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Focal Beryllium BMW


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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: January 23, 2009 at 3:01 PM / IP Logged Link to Post Post Reply Quote robolop

A couple of years ago, my wife was making ( read: painting) christmasballes, to hang in the christmastree. She also hooked on making special things

When i looked at the plexy balls, i know, that sometime, i could use it for another project  Well, ladies and gents, IT'S TIME

These are the plexy balls, you can buy 'm in every size. (according to his wife)..
:D:D:D
A old friend of my Earl Zausmer build 12 or 13 years ago something like this.

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Then I made a hole in the bigget bal, so the little one stands a bit 'in' it

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On this pic you can see the ball with the speaker, stands a bit further away. I did this on purpose.
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pic with speakers in it.

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whiterob 
Copper - Posts: 351
Copper spacespace
Joined: July 22, 2007
Location: United States
Posted: January 23, 2009 at 7:41 PM / IP Logged Link to Post Post Reply Quote whiterob
I've seen people make something like this using plexiglass balls as a mold. I have not seen any one actually put the speakers in the plexi balls though.
robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 20, 2009 at 3:03 PM / IP Logged Link to Post Post Reply Quote robolop

pic of the car:

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There is still some adaption work.

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This will be the Sub-box.

The piece I wanted to cover in Carbonkevlar, I painted black, to be sure the layer underneath won't show.

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milled some rings to put the woofers in.
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Here a picture of the bottomside, where he made wholes , to let the sound flow outside.

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Still some more polyester work to do.
Did some preparation to stretch the cloth nicely.
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The wholes you can see in the alu, don't worry about it.

It'll be covered in CF..
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The next thing on the list is something very difficult.
The connections of the speakers he'll make in copper, of 5mm thickness.
Cables are so boring

some cupper

5mm thickness, more didn't fit in the speaker.

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Copper connections are ready.

made a model first, took a mold, and fold it the same way.

Sawed it all, rubbed it, and polished.

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On this picture you can see he putt a whole in the bottomside to connect the cables.

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The cupper wil go to the middle, so I made a alu plated where the bars fitt right on in.

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alu triangles bade in a little CF.

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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 20, 2009 at 3:05 PM / IP Logged Link to Post Post Reply Quote robolop

some more CF.

This is the bottom plate where the box is put on.
sprayed it in black offcourse, don't want the colour of the wood come throu
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Varnished it for the first time, rubbed some more, varnished, rubbed, varnished, rubbed, ...........

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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 20, 2009 at 3:06 PM / IP Logged Link to Post Post Reply Quote robolop

started to make the bottomplate. She will be around the BOX and rest on the chassis of the car. did it as good as possible. Leveled it with waterleveler.

Once this plate is right, you take the messurements always from this plate, so it has to be 100% correcT.
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milled to upperboard

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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 20, 2009 at 3:06 PM / IP Logged Link to Post Post Reply Quote robolop

Started to make a hinge. He went to see the store, but they didn't had what he needed. So got some aluminium ..

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The meaning of this hinge, is that the amplifier can go up. So the crowbar needed to be something nice.

Cause the crowbar wil be very shot/small, he made it strong enought. (15mm thickness)

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there are nicer things in life to do, but when it's finished, it was worth the work in his eyes.

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Against the alu tube, he's going to weld a piece to, where he can hook the amp on.

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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 20, 2009 at 3:07 PM / IP Logged Link to Post Post Reply Quote robolop

Then I started to tair apart the Alpine CD player.

Did away the front, and made some trolleys to fasten the thing.

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here you can see the front of the CD player

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The ALU- box where the amp should come is foreseen with the hinge.

This one, he screwed on. I going to try it'l go this way.
If not, he can always weld it on...
I doesn't want to try it now, cause he's afraid it all bend of the heat.
But it's a final option...
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Will look like......

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put some movement in the amp.

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Made a fiberglass plate.

Here will be some change soon, but you have to start somewhere.

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found some vents that you can take from each other.

These are from aluminium, but the frame they're in, goes in the bin.
There will be an -minor modded- version of it
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2 pieces to place in the vents, so the cooling on the amp will be better.

Some chinese sticks

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put them together

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painted with polyester/fiberglass

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rubbed and filled, filled and rubbed

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this will be carbonized

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The pieces are finally done.

all that work, pppfffffff, but it was worth it .
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Here's a picture from the front. You can see a V where everythings slides into.
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Then he fiberglassed a little alu piece that is fastened bigtime.
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In the whole those things are layed into, fiberglassed a firm alu bridge, and there the backside slides into.
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These things have to come out really fast, cause his GPS and CD loader is behind it.

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I made a grill, to cover the sub-box.

The frame es milled out of MDF wood.
Here you can see the top of the upper ring. This one, you will see, and will be covered in Carbon
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On the picture, you can see he miled a little ditch.

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covering the frame in Carbon

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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 20, 2009 at 3:10 PM / IP Logged Link to Post Post Reply Quote robolop

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
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this is the bottomside. You see I made some screwbusses in it.
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 Made an alu ring of 3mm thick for on the bottomside. Must be very solid so the grill can't bend in the middle.

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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.

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The middle ring going into Carbon Fibre. Need some more layers of epoxy though..

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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 20, 2009 at 3:11 PM / IP Logged Link to Post Post Reply Quote robolop

Took the uppermill and started the outer-ring.

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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

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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.

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.
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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

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Then, I put the actuartor on a alu plate of 4mm thick.
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The fiberglassed part where the motor will be put on tight, is as good as ready.

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I sprayed this black. Those who read all thread, now what that means .

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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.

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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 .

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The CF piece, to put the motor on is ready... I did some long long long rubbing, but it was worth the effort.

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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 20, 2009 at 3:25 PM / IP Logged Link to Post Post Reply Quote robolop

These are a few pics from the install i'm currently building. The install is still in progress, and I'll post everything what's already made.

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