BERYLLIUM BMW 323ci.

[robola 46]

I put the uppermil on to the carbon slat, where the vents are coming in to.

First I rubbed the epoxy nice and straight, and stopped with a grain 2000.

Then I taped the slat, so I couldn’t make any scratches with the mill.

To drain the wholes smoothly with the copy-mill, I put my MDF slat underneatch it, so I could mill the wholes nicely

On the first view, this was done pretty well. I was a bit scared that the carbon fibre would be that straight, but that wasn’t the case.

After that I used another mill, to make the roundings I needed.

After measuring this about 10 times, I did the job.

I went pretty well actually, till I saw that the MDF slat wasn’t 100% centered.

Here you can see the obviously

You see some carbon fibre hanging on the underside.

A little mistake I made, is that I didn’t drawed out the aluminum slat on the mdf slat under it. A little dumb from me.

Here you see that what I milled out of the rounding isn’t 100% centered.

Tomorrow I’m going to try to solve this all. If I don’t get a solution, it all goes in the bin, and I’ll make a new one.

The carbon side panelswhere the amplifier is going to be, are also finished already.Here’s enough epoxy on, so now I just have to rub it all tight and varnish it all.

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The slath were the vents are coming into, just landed NEXT to the bin.

I did a great job in milling down the carbon fibre, but the things I polished, were ruined.

Looked for rubbing it down, but that wasnt possible without touching the carbon fibre.

I put it away for a couple of hours and did some thinking.

This is what it is now:

I took a piece of 8mm thick aluminum, and drilled 4 wholes into it.

After that I rounded the edges

Here you can also see I went a couple of mms deeper.

After that I removed all that was inside.

Where have we seen this again?

The custom made slat on the outside

Then I worked on the backside, and touched it with the mill…

Then I made a whole in the carbon slat.

This was the hardest thing to do today.

Itll all look like this.

On the aluminum piece will come a great deal of polishing, but ….were used to that.

Once its done, Im long forgotten about those hours of polishing.

Oh yeah, thank you Jeses for letting me have all my fingers today, dangerous day today

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One of my friend did a fotoshoot of my car.... here a sneakpreviuw, the rest will follow soon.

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Occupied myself for about 8 hours with rubbing the aluminum parts who need to be polished.

It's a work that needs lots of, lots of time. And when you don't put an effort in this, you just won't get a good result.

First I rubbed it dry with a 120 and 240, after that I took a 600 wet, 800, 1200 and stopped with a 2000.

The trolley that lays on the foreground already got a kiss from the brush to see if the result was fine.

Of this piece, the topside will be covered in carbon fibre.

The CF parts that come next to the amp are also finished to get a final layer of varnish.

[robola 46]

I’ve been able to polish all the aluminum parts today, what wasn’t that easy to do.

Don not underestimate this job, it’s not as easy as it looks. It’s also dangerous, and very time-consuming.

And, when you finished it all, you’re as black as working in the cole-mines for 14 days… but a shower afterwards can help a lot.

So, this was the most dangerous job to do.

Here I just needed to do the side.

When I made up my mind about how to make this, I was planning to polish the upperside as well… But afterwards I decided to cover it with carbon fibre.

The 4 toggles where the plexi will lay into.

What do you mean, it doesn’t shine? You can see what’s hanging on my wall

The slots what come on the front and backside.

Mounted it all

think, that when the upper side will be in carbon fibre, it’ll look DOPE

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The plate where the vents will get into, I brushed this also, with this as result !

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All the carbon parts that will get around the amplifier, are varnished.

Here the result.

About the parts from the sides, I was a bit afraid that I won’t match the amplifier. This is the result, and I’m very pleased wit hit.

Here you see the lath that comes on the front. I don’t think you’ll be able to see anything ot it, but the finishing touch is there!

The polished aluminum plate blends in 10 times better on the black carbon.

This is the upper part of the cover. I painted it black, so probably you can guess what I’m planning of doing…

So the inside of the amplifierbox is completely finished.

In spite of all the work I’ve done, I’m superhappy with the result

[robola 46]

This will be the front of the amplifierbox. First I made a model in 5mm thick MDF.

Drawed it out on the aluminum of 10mm, and saw into it.

Taped the MDF plat onto it, and tomorrow, it’s mill-time

In the meanwhile I’m baking some carbon cookies in the oven.

The alu piece that will come onto the front of the box, is finished!

Cut out the wholes with the uppermill.

This time I tried GT7 as lubricant, and I must say I’m very satisfied about this product!

Here I grabbed out some more mm’s between the wholes

This is the back side. You can see I grabbed out some more mm’s over the entire surface.

Here in will come a carbon piece, with my logo on it.

Once finished, I spent a big amount of time rubbing it all down.

Afterwards, held the piece under the polish-brush so it shines a bit

The small piece of carbon fibre, that’ll come on the back, is baking as we speak.

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The cover of the amplifier got a total of 6 layers of varnish. I also used new epoxy, wich I find not so good.

There came a lot of little holes in the carbon fiber.

Cause there is so much varnish, I had to rubb it all flat and equal with the

block.

Here you can see how much is really on there.

After some firmly rubbing with a 2000, I started on the aluminum.

Cause of the rubbing, it got mat here and there.

Had to do this by hand, and used some UNIPOL for this.

Offcourse, the result here is not what it was before.

Using a machine would made this 10 times better.

After this I polished the carbon fibre.

Finally, the final result of this piece.

The hard part of this piece is that the transition needed to be descent, and it came out well.

Mounted the rings again.

For those who think this is done… you can forget it.

Before I began covering the alu plate with carbon fibre, I mesured it.

The alu plate was 8.2mm thick. Now with the carbon layer on it’s 9.7mm thick.

That means that everything came up 1.5mm…So the plexi won’t fit that nice anymore.So I have to shorten the rings/toggles about 1.5mm

[robola 46]

I got the chance to finish the aluminum sides of the amplifier-box.

You’ll see that I made the same wholes into the upperside, like there are in the toggles where the plexi is on.

It’ll look like this on the outerside.

Here it’s mounted on to the box. You can see I put some fine gauze on the top. Later I’ll explane why I did this.

Behind the 5 wholes in the bottom there’s a piece of carbonkevlar.