Robola 46's BERYLLIUM BMW 323ci.

[andym85]

Here are some aluminum parts I'm going to work with in the cover.

The 9 tubes you see on the fore-ground are from anodised aluminum.

On the backside you see 3 threadstaff of m6

Here you see why I had to sink in the m6 screws.

A picture here from the complete part, with the plexi on.I will have to screw this tight still, so I stays right where it needs to be.

The whole part makes me feel that the amplifier is behind bars, in jail.

[andym85]

As you may see, on the left, and on the right, I have a gap of about 4cm for the cables (for the amp)

As you may know by now, I'm not a fan of cables in an install, so...

I made 2 pieces of carbon fibre for the sides, so the connections will not be visible.

First, I made a fiberglass mold of the amplifier.

Once this was ready, I rubbed out the lines of the tape.

finished, so put on a layer of carbon in there.

By doing this , I learned something really stupid.

Because I never took a mold of thins I make, I don't have the necessary products here to do that.

So I solved this on a idiotic way, really.

I just bought some plastic tape of 50cm? 50mmwss wide.

Taped it in the mold, and rubbed it in with polishing wax.

here you see the tape.

So you see, somethings will go with simple methods.

After this all, I put in the disc in the carbon fibre, and rubbed the piece nice and straight with my giant abrading block.

This is what I needed!

To tighten these 2 pieces, I have to make some aluminum toggles on the amplifier, so they connect with the rest nicely.

The carbon plates still need some layers of epoxy.

[andym85]

If made 2 toggles to tighten the carbon pieces onto the amlpifier.

Here , everything is on the amplifier.

You can see I only put in 1 screw.

The carbon fibre sits in between the aluminum and the amplifier, tight as a rock.

When the cover is on, you aren’t gonna see that miserable screw anymore.

I also worked on the 2 sides of the amplifier-box.

I milled out as many aluminum as possible, where the cables will have to come.It will be tight, but we like it that way

[andym85]

On this aluminum slat, I'm going to mount 4 little vents who gives some extra cooling on the PPI.Cause the "feed" part of the amplifier is on the right side, I also did it on that side.The aluminum plate is 4cm high and the vents are 2.8cm big.

These 4 wholes, I drilled with a "step"drill

Then I glued the slat on a piece of mdf, and made the wholes as big as the aluminum with the uppermill

Then I took the mill, to round up the frontside of the aluminum, and so it's all milled nicely.

Then I milled the backside of the slat diagonal

after that I, carefely, drilled the wholes, who will serve to tighten the vents.

I used some normal wood-screws fot that.

This is how it looks on the frontside.

The meaning now is to polish that slat of aluminum, and put a layer of carbon fibre over that.Once this is all finished, I'm going to put in the uppermill again, to round up the frontside.

The meaning is that you'll see the aluminum that's rounded.

If this is possible, I'm not sure. HAven't done it myself either...but , there's a first time for everything!

[andym85]

The aluminum slat where the vents are going into is firmly rubbed down.

Then I polished the roundings of the holes.

This aluminum L-slat is to finish off the frontside of the amplifier..

Here you see I preserved it with a layer of carbon fibre.

[andym85]

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.

[andym85]

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 wasn’t 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 mm’s 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.

It’ll all look like this.

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

Once it’s done, I’m long forgotten about those hours of polishing.

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

[andym85]

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

[andym85]

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.

[andym85]

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