Robola 46's BERYLLIUM BMW 323ci.

[andym85]

After all that it was time to give it all a nice shine!

For this i used a soft brush with blisters on it.

Again, i applyed a bit of STAR WAX BLACK on the machine, and just let the machine do all the work.

After that, it was again time to bring out the microfibre cloth.

Next step: wash the car (again...)

For this washing i've used water and MOTO QUICK.

This product is used to remove all the greasiness from the paintwork in preparation of all the next steps.

Concerning the car: i've now moved on to the final step of the outside.

I've appyed a layer of TITAN WAX.

I gave it all a good rub with the included cloth.

The product has to stay on the car for about 24 hours before you can rub it out.

I treated the trunk at first, just to see if the product got easely rubbed in. That was a disappointment i must say.

I think i have to eat a lot of rice pudding so that my arms get more muscular

[andym85]

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.

[andym85]

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’ ?

[andym85]

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.

[andym85]

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.

[andym85]

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.

[andym85]

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..

[andym85]

I made 4 aluminum supports of 8mm thick.

These have the same rounding as the plexi.

First, I made a mold out of mdf. After that, I drawed out the aluminum piece, and sawed it out.

after that, with double sided tape, I sticked it all together.

Once this was done, I held it all to the copy-mill

Here a picture of how it will look.

The next step was to “modify” the supports, cause it looks a bit simple like this.

The lower plate is the model I made.

It’s only 4mm thick.

In the piece I needed, I got rid off the aluminum, and sticked it all together again, and then got the mill back in there.

Looks way cooler according to me.

The other 3 will suffer the same cause.

The pattern looks good, but the support still doens’t look the way I wanted too…So I guess I’m going to modify this some more.

[andym85]

Too some issues I didn't get the chance to do much on the ICE.

But now , a 'little' update.The 4 toggles where the plexi will lay on to are finished

The alu-plate of 8mm where the toggles will get onto.

Offcourse, some holes were needed here, otherwise you wouldn't be able to see the amplifier.This is the mold I made of 4mm thick MDF wood.

Layed this on the aluminum and drawed it out

Then, I drilled some holes, and sawed it all out with the electric jigsaw

Pasted the MDF mold on to it.

Then I mounted my upper-mill once again under the table to do some dangerous stuff

Here the result

[andym85]

Then I 'modified' the outer toggles.

Because a M6 bar with screw-thread will get into this one, I had to drill the hole much bigger, so the nut is sunk into it all.

Made it big enough so it would be possible to get a 10 on there as well

In all toggles I tapped a screw-thread of M5, to fasten them at the bottom

Once I had all of this, I could begin the mounting.

The front and back of the thick plate, I milled in a gap whereto I screwed a big L onto.SO I have a nice finishing touch, and the plexi is tense.