Focal Beryllium BMW

I fastened he plexi copula in the meanwhile. In the plate where the screws rest, I milled a groove of 1 centimeter and filled it up with polyester.

On the bottomside, I mounted a led-strip.

Here you can see the blue light, shining through the speakers, find it kinda cool

Pictures in the dark.

Look what a reflection I get with all that varnish

These are some pictures where I put on some more light from above.

This is about it for the sub-box, yep, eventually, there has come and end to it

The kidneys and the windowsmoldings are painted deep gloss black and mounted back on.

I don’t find the front that busy anymore

Some buddy’s asked me if I had darkened my windows…lol

The car will stay like this , this season, it lookes fine for me.

This is the plexi where it’s all about

Turned it all over and drew out the whole.

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.

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.

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

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

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’ ?

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.

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

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

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

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

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

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.

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..

I made 4 aluminum supports of 8mm thick.

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.

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.

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

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

Then I 'modified' the outer toggles.

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.

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

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.

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

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 you see, somethings will go with simple methods.

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.

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.

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.

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.

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.

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.

Robolop,

Where did you learn to do all of this. I would love to create something like this for my truck or at least learn to use alu like you do. I am gonna take a wide guess but Im guessing your not from the states? I was wondering what kind of milling tool you used so I can look for one to start fooling around with on some projects.

  Oh and by the way your car is looking awesome. The work you do is pretty amazing. How many hours have you put into this?? Have a good one man!

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

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