BERYLLIUM BMW 323ci.

[robolop]

pic of the car:

There is still some adaption work.

]

This will be the Sub-box.

The piece I wanted to cover in Carbonkevlar, I painted black, to be sure the layer underneath won't show.

milled some rings to put the woofers in.

Here a picture of the bottomside, where he made wholes , to let the sound flow outside.

Still some more polyester work to do.
Did some preparation to stretch the cloth nicely.

 

[robolop]

Re: BERYLLIUM BMW 323ci.

The wholes you can see in the alu, don't worry about it.
It'll be covered in CF..

The next thing on the list is something very difficult.
The connections of the speakers he'll make in copper, of 5mm thickness.
Cables are so boring

some cupper
5mm thickness, more didn't fit in the speaker.

Copper connections are ready.

made a model first, took a mold, and fold it the same way.
Sawed it all, rubbed it, and polished.

On this picture you can see he putt a whole in the bottomside to connect the cables.

The cupper wil go to the middle, so I made a alu plated where the bars fitt right on in.

alu triangles bade in a little CF.

 

[robolop]

Re: BERYLLIUM BMW 323ci.

some more CF.
This is the bottom plate where the box is put on.
sprayed it in black offcourse, don't want the colour of the wood come throu

Varnished it for the first time, rubbed some more, varnished, rubbed, varnished, rubbed, ...........

 

[robolop]

Re: BERYLLIUM BMW 323ci.

started to make the bottomplate. She will be around the BOX and rest on the chassis of the car. did it as good as possible. Leveled it with waterleveler.
Once this plate is right, you take the messurements always from this plate, so it has to be 100% correcT.

milled to upperboard

 

[robolop]

Re: BERYLLIUM BMW 323ci.

Started to make a hinge. He went to see the store, but they didn't had what he needed. So got some aluminium ..

The meaning of this hinge, is that the amplifier can go up. So the crowbar needed to be something nice.
Cause the crowbar wil be very shot/small, he made it strong enought. (15mm thickness)

there are nicer things in life to do, but when it's finished, it was worth the work in his eyes.

Against the alu tube, he's going to weld a piece to, where he can hook the amp on.

Then I started to tair apart the Alpine CD player.
Did away the front, and made some trolleys to fasten the thing.

here you can see the front of the CD player

The ALU- box where the amp should come is foreseen with the hinge.
This one, he screwed on. I going to try it'l go this way.
If not, he can always weld it on...
I doesn't want to try it now, cause he's afraid it all bend of the heat.
But it's a final option...

Will look like......

put some movement in the amp.

Made a fiberglass plate.
Here will be some change soon, but you have to start somewhere.

found some vents that you can take from each other.
These are from aluminium, but the frame they're in, goes in the bin.
There will be an -minor modded- version of it

2 pieces to place in the vents, so the cooling on the amp will be better.

Some chinese sticks

put them together

painted with polyester/fiberglass

rubbed and filled, filled and rubbed

this will be carbonized

 

[robolop]

Re: BERYLLIUM BMW 323ci.

The pieces are finally done.
all that work, pppfffffff, but it was worth it .

Here's a picture from the front. You can see a V where everythings slides into.

Then he fiberglassed a little alu piece that is fastened bigtime.

In the whole those things are layed into, fiberglassed a firm alu bridge, and there the backside slides into.

These things have to come out really fast, cause his GPS and CD loader is behind it.

I made a grill, to cover the sub-box.
The frame es milled out of MDF wood.
Here you can see the top of the upper ring. This one, you will see, and will be covered in Carbon

On the picture, you can see he miled a little ditch.

covering the frame in Carbon

 

[robolop]

Re: BERYLLIUM BMW 323ci.

This will be the inner-ring, what goes in the grill.
First I mild a MDF wooden ring and rounded the edges. What you see now is the upperside. Comes in CF btw

this is the bottomside. You see I made some screwbusses in it.

Made an alu ring of 3mm thick for on the bottomside. Must be very solid so the grill can't bend in the middle.

Here you see the 2 parts on each other. Between there's 2mm place for the innox plate on the outside, and the alu from in the centre.

The middle ring going into Carbon Fibre. Need some more layers of epoxy though..

Took the uppermill and started the outer-ring.

Started to begin polishing. Is a heck of a job, people who polished with heavy machinery before know...
It's kinda hard to do this without the brushes hacking into the alu..

I did this:
Screw the piece on a piece of wood that you can hold on tight.
1) you won't burn ya fingers/hands on the alu
2) the brush can't bite himself into sth

 

[robolop]

Re: BERYLLIUM BMW 323ci.

As you can see, the whoel sub part is see-able and yet, it's covered with real glass I can clean as much as he wants, without making scratches.
The nice thing about this grille, is that I made it with a simple milling tool. This is the proof everyone can make something really nice, with non-expensive equipment.

The grill is almost complete. for now, no Focal Logo's anymore
althought...
The next work on the list is for next days, maybe weeks.
The actuator, that bringt the amplifier to life, will get a nice place.
For those who forgot, this is how the motor was placed.
This was only to see if the thing worked like I wanted.

The meaning is, if you take the left carbon piece away, you see the motor and the cd-changer. If I wanted to show this, it must be made SHOWABLE

Then, I put the actuartor on a alu plate of 4mm thick.

The fiberglassed part where the motor will be put on tight, is as good as ready.

I sprayed this black. Those who read all thread, now what that means .

This will be the alu plated where the motor will locked on.
As you can see, I made 4 big wholes in it. Under these, put a carbonkevlar plate. The look will be a little bit better I think.
Also you can see I made a alu piece with M5 screws. Here will be a "bar" in connection with the amp.

I took everything on a trip to polish-land.

The fiberglass part that comes under the motor, is already covered in a layer of carbon... needs some more epoxy.

Not simple to cover it in carbon, but it worked.
Couple of layers of epoxy are needed, and then rubb the whole piece, while working on the sides..

Damn, this piece looks great, but you're not going to see much of it .

The CF piece, to put the motor on is ready... I did some long long long rubbing, but it was worth the effort.

 

[robolop]

Re: BERYLLIUM BMW 323ci.

This is how the motor is beeing placed; You can see I put an little alu cover over the bar from the motor, not easy to find...

This is the same material as where the engine is screwed on.

Made an extra piece of carbonkevlar to fill in the big wholes on the bottom of the motor.
A little more contrast with the CF.

The picture is taken when you're standing right behing the trunk. Now you can see it all.

Now the big question is, WHY THE HECK make such a big piece of CF, but i wanted to be sure that EVERYTHING looks perfect, from what ever angle you look.

Again with the neon.

This will come under the right vent, just for looks.
On the leftside we have the CF piece where the motor is at, so it looks more the same on the right side went you look through the vents.

I'ts time to rebuild the doorpanels.
The doorpanels i using are secondhanded. So the car remains complete, and I doesn't have to drive without panels all winter.
Demounted some stuff.

Started taking off the leather. awefull job

The 16cm FOCAL speaker is taking approximately the same place where the original speak is.

In the meanwhile , I let the rings mild nicely.

I milded some MDF wooden rings to tighten on the doorpanel.

To lock the speakers tight I made a extra alu plate of 6mm thick.
Here I can use the screws that came with the FOCALS. These are special screws that click-in the grill.

This is an seperate little cap that goes on top. This model will be editted more.
This will come nice when it's finished.

 

[robolop]

Re: BERYLLIUM BMW 323ci.

Designerdepartment going at full speed
Worked on the ring where the speaker goes in, more smooth now.
Step by step, till it workes out to something he likes;

On picture, maybe it doesn't look so good, but IRL it looks fine. The forms i made also come back in the original panel. So it's more styled this way.

Here a couple of pics of the original doorpanel, to compare more easy.

And this is what it's going to be. The door, on the speaker, gained 2cm more to the inside of the car. This is what I had to do to get the speaker in there in a good way.

The seperate polyester cap, that goes over the speaker, will come in silver, like the trim.
This will contrast with the rest.

Picture with the grill.

If I look at this all, I think it doesn't contrast to much with the lines, shape of the original panel.

Has to be rubbed and finished some more.
On the backside of the panel, maybe there will come a little light, that shines when the door is opened. Partially to fill up the big piece.

 

[robolop]

Re: BERYLLIUM BMW 323ci.

In the meanwhile I made a whole into the doors platework, behind the speaker.
You can see the windowglider. Just nog touching the speaker.

Made some more parts, to fill up the other wholes.

On the background, there's a alu plate of 4mm thick. Very hard and strong.
In the middle you can see 2 Carbonkevlar parts. I made em as thin als possible .
On the foreground you see 4 little rings I made, to screw the doorpanel extra tight.

If you look to the second on the right, there's a little rubber he pasted on. On the place where he screwed it. This to prevent resonance.

On the picture you see a little pole picking out. That's MEGA IMPORTANT.
Behind the speaker, there'll be another screw, so we can attach it even more in the middle.

Everything mounted:

This won't be the end of the door. I has to make some tiny wholes airtight, but that won't go untill the has all the material to fill up the sound.
All I makes, will be filled up with this material. What exactly I going to use, he's not sure. we'ill keep u informed.

As you can see, I putting a lot of work into all this. And more work is coming up so the sound won't be lost...

I think this is a type of work, that is underestimated be many people. But the work will pay of in the end, that's what we are sure of...

 

[robolop]

Re: BERYLLIUM BMW 323ci.

As you can see, het got the disc in there again. Disced a ditch in there so I gots some place to get the overflowingin leather away.

The alu and the pole I got on there so it all stays equal when it gets overlayed.

you see, the plates can be rattled off.

as you guys can see, the bottom part is already painted black, you all know what happens then...

indeed, CARBON TIME

The bottomsides of the doorpanels will have to be done in CARBON FIBRE.

So a dificcult object to get in the Carbon fibre. But we must admit, it's done nicely..
Many time was put into preparation the prevent the CF - overlay to got wrong at any place.

This annoying little side was one of the many things that could go wrong.

Also, I was satisfied to get the little lamp in there. makes the piece a bit more interesting then one big lumb piece.

This is the ditch I disced into the panel. For those who don't get the picture. When it's all done, the upperside of the panel will be overlayed in leather. Then I needs a little space the get rid of the too much leather.
To get a nicer finishing off

You see on this pic that everything at the bottom is in CF..

Now the big work is to get it all nice and flat. Put some more layers of epoxy on there till it's all nice and smooth.
so, lots of work and patience...
This is the 3th layer of epoxy.
Rubb it all down flat and equal everywhere, and then another 4th layer of epoxy.
Some pics

 

[robolop]

Re: BERYLLIUM BMW 323ci.

After firmly rubbin' the epoxy, I added another layer op expoxy.
Maybe it's not so visible on the pic, but it's quit flat already.
4th layer of epoxy.

Now it's important to rub the last layer good. Start with an 800 and end with a 2000.

I also found the same black leather to cover the panel like the original one.

http://i82.photobucket.com/albums/j272/robola/DSC02768_resize.jpg[/

After firmly rubbin' the epoxy, I added another layer op expoxy.
Maybe it's not so visible on the pic, but it's quit flat already.
4th layer of epoxy.

Now it's important to rub the last layer good. Start with an 800 and end with a 2000.

I also found the same black leather to cover the panel like the original one.
[IMG]http://i82.photobucket.com/albums/j272/robola/DSC02764_resize.jpg

 

[TobyNik]

Re: BERYLLIUM BMW 323ci.

'WOAH!!!!!!!!!!!!!!! Awesome......but I wonder how much the car weighs when it's al done?


But still Awesome......just curious, how much $$$ going into this project???

Cheers!

 

[JLMC]

Re: BERYLLIUM BMW 323ci.

mine oh mind!!!!
:yikess: i tot such work r usually angmoh like to do it..
wow..u r incredible! r u pro taking some competition lately?
:laughlik:

 

[TobyNik]

Re: BERYLLIUM BMW 323ci.

mine oh mind!!!!
:yikess: i tot such work r usually angmoh like to do it..
wow..u r incredible! r u pro taking some competition lately?
:laughlik:

LHD car........

 

[oneHeadlight]

Re: BERYLLIUM BMW 323ci.

Very impressive installation work.

The door panel... i am curious.
With the midbass going at the door, the panel still vibrates. The soundproofing has to be done right, but even that, are you doing anything else to "fasten" or secure the panel more tightly ? The plastic clips are not strong enough.

 

[Herman]

Re: BERYLLIUM BMW 323ci.

Nicely done up bro.
Looks like a lot of effort put inside...

 

[Violin]

Re: BERYLLIUM BMW 323ci.

Woah Genius !!! Very impressive

 

[marklee]

Re: BERYLLIUM BMW 323ci.

I've seen this build on some other forum before...was some time ago...