Robola 46's BERYLLIUM BMW 323ci.

[andym85]

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..

[andym85]

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

[andym85]

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.

[andym85]

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.

[andym85]

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.

[andym85]

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.

[andym85]

Thanks dudes for the positive comments.

I started this project 2 years ago. A long time ago they asked me to post the project here, but I've kinda forgot about it.

The things I'm about to post now are finished for over a long time.

At the moment I'm finishing up the amplifier.

You'll get to see this in a couple of weeks, then you can follow the project day to day, in real time.

As I said before, I'm not bothered with someone's bad opinions, sometimes maybe I can learn...

The time I'm putting into this project doesn't bother me... I'm trying to enjoy the things I do as much as I can, and try it to do as GOOD as I can.

Enjoy dudes!

[andym85]

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.

[andym85]

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.

[andym85]

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.