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Let's get technical with the wheel load rating.

F30 Brake Clearance The obvious issue with designing a wheel is fitment.  If I'm going to achieve Objective 2 (creating a product) it needs to be capable of fitting more than just my own car.  Once I locked in the overall wheel and tire size to 18x9 +30 with 255/35-18 tires, a specific meaty tire combo that fits all corners without wheel spacers, I needed to concern myself with brake caliper clearance. Fortunately, Brembo is great about supplying just enough data to CAD up some clearance volumes.  (See here)  There are a lot of BMWs, the Volvo S60R, and plenty...

Preface So I'm developing wheels, brake components, and shocks but doing it the PdV way, which is to say I design, engineer, source, assemble, and ship.  There is no PdV machine shop, no CNC coding in house, no anodizing baths.  I rely on trusted manufacturers from my history in the professional racing market as much as possible to ensure quality whenever possible. In the case of the wheels, they will not be 100% Made in the USA.  Mostly due to US manufacturers simply costing so much just for the raw material and often requiring minimum order quantities of 50 or more.  A...

Its well under way now.  I'm expecting to have all CAD drawings out for quote before the night is over.  The goal is quite simple.  Avoid designing everything from scratch by using the most expensive parts from another company that is meant for another car and modifying where necessary to build an S60R specific damper set.  I want a rebuildable custom tuned set of dampers including rear spherical shock mounts (if you need them) for around $1,700.  If I can add a rebound adjuster and still hit that target I will make it part of the standard package.  If I can't...