RSS Harness bar - observations, questions

Hello, Just about done installing the RSS harness bar in my '12 Cayman R.. Wondering if others on the forum who have installed RSS bars themselves can chime in. I am a fairly experienced with working on cars -- I've installed suspension, I've rebuilt/midified braking systems, diffs, and even a few small block chevy 's and ford motors. Having said that, fitting the RSS harness bar has been an incredible pain. While the bar is well built and finished, the design results in a very difficult install with too much trimming of interior bits. Currently, they are the only readily available harness bar for the Cayman that I could find. RSS does not include nor have DIY instructions for the bar; I spoke with someone at RSS and stated that a premium product like the RSS bar should have quality instructions. I was offered assistance from one of their techs, should I need help. To be clear, I am not knocking RSS -- in fact, I plan to buy (at least) their control arms. Anyhow, too my question... I am in the final stage of the install, but have one problem: I am unable to line up the bolt hole for the seat belt guide if I use the black metal 'shim' that the guild rests in. If I leave this off, I can start the bolt without issue. With the shim under the guide rod, I can not get all the holes aligned sufficiently to get the bolt started. It seems that I need to slightly trim the leading edge of the harness bar foot plate to allow the black shim to align correctly. I realize that sounds a bit cryptic, but if you've done this install before you will know what I am talking about. Any thoughts or experiences with this? Thank you, DJM

I left those little black pieces off! I found it impossible to align everything just as you did. The trickiest part of the installation is the trimming of the panels and actually fitting them back on. It is a tight fit but the bar is sturdy to say the least. I will move to a BBi full bar when I get my motor and trans situated the way I like it. Good luck

Thanks for the reply, cpturbo. I am glad to hear I am not the only person to have problems with the black plates. Currently, the bar is mounted, sans plates, but I did put a large grade 8 washer where the black plate would have been. This serves to spread the load in the area, and adds 'height'. The RRS harness mount 'foot' plate + the thickness of the washer roughly equals the thickness of the black piece. Agreed WRT the trimming -- it was a hassle, but is is now done, and I am pleased with how the bar looks. Cheers, DJM

Can you shoot me pictures of the trimming. I have not done mine, yet. I am unsure if I am going to put it back. Thanks

Sure, I'll post some pics later this week. I spoke with a tech a RSS and it turns out the funky black piece is supposed to be omitted! So, all good -- would have been nice to know this prior to install! Cheers, DJM

Yes, I was surprised about the lack of instruction or help from RSS. Here are a few pics of my trimming. Note the horizontal cut.

I am still a little disappointed that RSS does not include some basic instructions with the bar; some thing showing where to cut the trim and, most importantly, that you do not re-use the small black shims. I wasted a lot of time (and frustration) this past Sunday trying to figure out how to get all the pieces to fit. A simple one page instruction sheet with 2,3, or 4 photos would be sufficient. Having said that, both email and phone contact with RSS has been pleasant and professional. When I called RSS today, I did not have to wait on hold, and the tech I spoke to was super friendly and was able to answer my question right away. Cheers, DJM

I understand the original DMC harness bar is available again. It was a much cleaner installation and in my opinion a stronger, more integrated unit. Anyone hear that they are available?

. I've look and the DMC harness bar design, and while I can easily see the DMC design is a *much* cleaner install, I am somewhat surprised you feel the DMC bar is stronger. The DMC bar relies on one long bolt on either end of the bar, placed up high with a long spacer. The "foot" of the bar ends is quite small. The middle aluminum plate will not add much strength -- the counter sunk screws will tear right though the AL if subject to serious stress. The RSS bar, despite the difficult install, is secured with a grade 8 bolt and the seat belt guide on each end. The "foot" of the bar end is quite large and spreads loads over a large area. While I cursed during the install, after I was done, I was pleased with the quality and engineering of the RSS bar. Cheers DJM

Thanks CBRacerX- The DMC Components bars are indeed back in production for the 2006-2012 model year Caymans. Thanks for the compliment. I have seen the RSS bar and it is a nice unit also, however it just uses a different mounting style than our DMC Components unit. Jim.

I know super old post, but wondering if anyone has pictures of the cuts they made on the trim . I"m guessing the trim needs a cut to let the bar through (both left and right, then the trim and bar go into place together and then the bar bolts in. I get that you need to make the cut out for the upright on the bar, but baffled at how to get it all in place.