Focal Beryllium BMW

I've created a crooked side on the back of the alu plate. This is because i'm going to work it into the polyester. This will make it easier to take out the piece.

Today i've polished the aluminium part.

Firt i've monted it on al MDF board to protect my fingers from getting burned. this is the result after 2 hours of polishing.

Here you can see how it should like like when it is finished. as i've said before: on the frontside of the crossovertray.

Then i started taking some serious risks.

The straight part needed to be "less straight" so i had to bend it. Therefor i created this.

So, now the part is ready to integrate in the rest of the booth. Now i need to make a piece to mount on the backside of the aluminium part. this will be made out of carbon. I've milled the model out of a 3 by 22 mm MDF board Afterward i had to mount them back to back.

This will be used as a mould.

I've made the thing so that i can use my 2 hands while working. Here you can see that the part can spin. I've used some paper tape. Afterwards i've covered it with a layer of carbon en 4 layors of polyester.

Now that evering thing is dry, the mdf parts are no longer needed.

So i'll use a saw to get them out. I'm not sure if it will work... It's a risk i had to take.

I continued taking the piece out of the mould.

I had to clean it up a bit. With an electrical saw i was able to remove the biggest pieces. So now you see why i made the 2 holes in the board. Much easier to saw! The rest was taken out by hand.

This is what it lookes like on the inside. In the middle you can see whe the 2 pieces of tape came together. after a few more layers of epoxy, it will look spotless.

Time to use my GIANT sandingtool.

On the other side i've sanded the curves of the allow part.

He're i'm using my router to mill out a piece of plexyglass.

The plexy will get mounted on the backside of the allow part.

This is how everything should look like in the end.

Don't go thinking that it's done! I planning on doing something special with the carbonpart, but i have to figure out if it is possible and if i have enough space to to it. Now i going to make the front to mount on the crossovertray. I still need to make a piece of plexy to mount on the rear of the carbon tray

Plexy mounted.

Here y ou can see how it will be mounted on the frontside

Here you can see the frontside of the crossovertray under construction.

I've made a board out of MDF with left and right exactly the same curves en mounted them in the trunk.

Afterwards i've filled it up with poly.

Once it was dry, i did the same on the left and right side.

I needed to adjust the backside of the poly part. Now it fits nicely and is just the way i wanted it to be.

Here you can see the crossovertray while opening.

Picture of the inside of the place where the crossovertray will be mounted in.

Next thing to do is shape the front of the tray so that is will fit for 100%.

It was pretty cold, but i found a way to keep me warm.

This is what my workshop lookes like after sanding on the tones of metallica's death magnetic.

As you can see, i've used a can of spraypaint to sand the curves.

Here's a picture of the finished part to fit on the front of the crossovertray.

On this picture you can see that it fits perfectly.

I've cut some glas to mount in the sidepanels.

Then i've sanded the carbon frames and prepared them to get painted.

The inner rail is mounted a bit lower than the rest. I'm going to fix everything with TEC7.

The carbon on the frontside is sanded and ready to get clearcoated.

The carbon part that will be mounted on the front of the tray is sanded and ready to be clearcoated.

In the meanwhile everything is removed from the car, so that it can get a final touch .

The carbon is already covered with epoxy.

I've been looking at the crossovertray, and it misses something...

In the front you can see the lights that i will be mounting.

I've made some changes to the sidepanels.

The straight part looked rathed ugly, so i've changed its shape. Here you can see that i've made the changes so that everything fits perfectly.

Clearcoated.

This is what will be mounted inside of the crossovertray.

It will be covered with carbon.

Some carbon parts are already clearcoated en ready to be installed .

These 2 alulinium plates will be used to guide the connectors from the crossover..

The inside of the crossovertray is also covered in carbon .

I've bent 16 massive kopper tubes to connect the focal crossovers.

Then i made the screws shorter so that it all looks better.

The holes in the aluminium are equiped with LED holders. Now i have a good isolation between the the kopper and the aluminium.

at the end of every kopper tube i'm going to fasten some speakercable.

The aluminium part which will become the frontcover of the crossovertay has been chromed .

The aluminium parts which need to guide the kopper and the piece inbetween the carbon will also get chromed.

This will make it easier for me to keep everything clean in the future.

These alumium plates are made to be mounted on the side of the crossovertray.

The previous ones have been removed because they didn't completely fit the rest of the design.

De aluminium parts on the side of the crossovertray have been replaced so the they have the same look.

Attention to detail...

I've used the old router.

Afterwards it all got polished.

This is the complete set up, you can see that everything worked out pretty good.

It's not easy perfectly line up the 16 tubes, and the fact that the connectionpoints on the cross-over aren't even in a straight angle doens't make it easier. The kopper connectors have been sanded and clearcoated

The aluminium parts which need to guide the kopper and the piece inbetween the carbon will also get chromed.

This will make it easier for me to keep everything clean in the future.

he you can see everything mounted in the car

this is the frontpiece of the crossovertray.

picture of everything opened. but i won't let ik open this much.

First i'll mount everything so that i can see what i'm going to do with it

the carbonworks...

This is the kevlar piece which will be mounted behind the aluminium on the side of the tray

I've modified the part used to hold the motor in to place.

I've made everything stronger here you can see how everything works

As you may know, I was working on the front bumper.

Meanwhile the bumper has been painted and I’m really satisfied with the paintjob. I also took the opportunity to paint the sub-box.So I had something to do while the paint on the bumper was drying.First of all, I made all the copper shine, and put a layer of varnish over it.Soldered the cables and put some shrinking tubes over them.The alu plate where the copper gets through got chromed. So keeping it clean, won’t be an issue any more

This is the result of lots of thinking.

Here the carbonkevlar and the plexy cupola is on.

Almost like fishes in a goblet

I’m really satisfied with this in particular. Trying to get the copper right where it had to be, was a really big challenge.

Still a lot better then some ordinary cables, don’t you think?