BERYLLIUM BMW 323ci.

[1992Chevy K1500]

There are no words to describe how awesome that thing looks. No matter what language you attempt to speak, there are no words.

[Marlo Stanfield]

I could see a feature in European Car magazine in the near future for this ride.

[JONESBOY]

nice work

[robola 46]

This is about all I did on the bimmer. I think it's a bit much, that I posted in these last days. For the moment I'm working on the amplifierbox again.

Worked more then a few hours on that box already...

But that's nothin' new I'm telling...

I'll post some pics tomorrow, and starting from next week I'll keep u updated as soon I have something interesting to share

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[robola 46]

This is the plexi where it’s all about

I tightened this with 6 screws

Turned it all over and drew out the whole.

Through this whole you’ll see the amplifier on the inner side.

Drew out how I wanted the slots.

On this wooden plate I’m going to mill the plexi. First I made a slot here and there, so the mill won’t touch the wood. So I have a nice bottom to work on the plexi.

Before I begun, I messured out how many mm I had to span/yoke the slath, to glide next to with the mill.

Once this was done, the muppet-show could begin

Nr1 is done, 3 more to go

When you look closely, you see I hit a little slath in the 2nd slot on the bottom.

I did this each time, so my plexi was always straight up when I was making the whole.

Done with milling, thank you lord I still have all my fingers.

Now the time has come to rubb and polish all of this nice and equally.

[robola 46]

I’ve managed to continue on the plexi plate. Before I started rubbing, I tape it.

When you even LOOK wrong at plexiglass, you’ve got scratches, so being carefull is the question

So I started searching around for a fine rubbing material, and this was the best tool I got…and the easiest.

On the left just a ordinary aluminum plate to do the straight sides and lines, on the right a thick pen with around it my rubbing paper, for the curvy parts.

To do this, it took me 5 hours to polisch and rubb it all.

The bottom where the plexi is screwed on to. The black you see is self-adheside vilt. I used this so I couldn’t make any scratches.

Inside of the ….’tank’ ‘box’ ?

[robola 46]

This thing will be my mold for bending the plexiglass. The cover, that comes onto the top of the amplifier, will be round, as you can see.

The MDF (wooden) chassis:

I covered this with an aluminum plate of 0.5 mm thick, so I got a nice rounding.

Also, I made it more round as it finally has to come.

Once the plexi is cooled off, it always brends a bit more straight again.

Hopefully this works, cause just on the mold, I had some reasonable work.

[robola 46]

This is the plexi I folded/bended with the paintstripper.

As you can see, I didn’t go as well as planned.

The problem with the paint stripper is that I doens’t heat everything at the same time.

This wasn’t the case with the plexi of the filtercase.

Just needed one fold there, so just had to heaten only one line.

With this big piece, the plexi glass cools don’t too fast, and the temperature isn’t the same everywhere.

So actually, a piece like that, has be heated in an oven between 120 – 150 degrees Celcius.

Since I didn’t find an oven in that couple of days, I bought me a plexi plate.

You can’t boggle for long now, do we…

I think this looks mucht better already.

These two pieces come on the sides. So you’ll get the idea it’s one big, entire piece.

[robola 46]

I worked some more on the two aluminum sides of the amplifier box, with the uppermill.

First tightened those thick plates.

Planted the mill.

The meaning here was to remove some millimeters, cause there has to come a carbonkevlar plate.

These are the sides that come on the outerside, to service as coverplate.

You can see on the holes, that the design here will be the same as the sides of the filtercase.I also milled away a couple of mm’s here.

Abraded it all firmly so I could polish the aluminum.

Here an example what it will look like

Have to give a rounding on these 2 plates, cause the plexi comes in between.

[robola 46]

Of these pieces of aluminum I’m going to make a frame, where the plexi will rest in.

The big plate i 8mm thick

The 8 other ones are 6mm thick

This isn’t going to be all, I’m going to use some other aluminum profiles also, but haven’t got the mesurement of those ones.

Many and many hours of millwork will get into this, but when it all works out like I have it in my head, it’ll be pretty cool.

Oh yeah, I’ll use some carbon fibre here too, but thought you gus will guessed that already..