Focal Beryllium BMW

Thanks dude, I'm trying to explain and do it as good as possible

Here you see the JL Audio's lying in the aluminum box. As you can see, these are pretty small amps.

The job now is to flow them nice into the box.

I find this logo of JL super beautiful, not sure if I'm going to use this anywhere...

The design departement is doing over time at the moment, but still not finished their job.

It has to be more cooler, more nice and more WOW then it was with the PPI.

That's a job that will not be easy, it'll be hard, but I'm taking the challenge. I've got time to work something out.

The works on the new amplifierbox are on hold for the moment.  Wich doesn’t mean I didn’t do anything this week, but now I have to wait for some stuff from over the water.  Too bad this can take a couple of weeks, but that’s the way it is now.

Once I had this, I copied this in 8mm thick aluminum.

Since there’s a rounding in the plastic where this comes against to, I had to make this on the backside of the aluminum too.

So it connects lovely on the side.

This will be the brake-pedal

Gas

Brake

Foot-rest

What you see here, are many hours of work. And it’ still not finished. I still have to do my magic trick still

I bended my brake pedal a little bit rounder. I think that must have been the biggest problem I could have, concerning the pedals that is.

I've managed to do this simple. On the front end I taped, on the top and the bottom, a little block of wood, with a little little plank on.

On the backside I taped a little block in the middle, and after that, put it all between the benchscrew.

Then I put a piece of barrel over the lever, so the lever gets bigger. Once I had this, it was simple to turn, and so bend the aluminum piece of 8mm.

The rounding now is the same as the original pedal by bmw

It took some time to grind it all firmly, and I stopped with a 1200 wet.

Now it was the time to make some inlay-pieces. First I taped the sloths with tape.

The I taped 2 roundels on each other, and placed in on the whole where screws come out.

I the meanwhile I made some iron little plates of 3mm thick. I had to do this, so I could taped some screws in there, to tighten it all.

Then I filled it all up with epoxy.

When it's all dry, I'll take out the plates, and they will have the same model als the sloths. buuuuuuuuuuuuuuuuuuut, they will be 2mm deeper then the alu.

The 2mm I need for the carbon and epoxy who will get on there.

I’ve baked some carbon cakes in my oven.

Offcourse, these need another set of epoxi-layers. The alu pedals go somewhere to get anodized, so they look exactly the same as the indoor moldings. Once I get them back, it’ll take some time to nicely cut out the little carbon pieces, and abrade them so they fit 100%.

I also did some tests with carbon fibre.

To do this right I had to use a Copperfield trick…and it worked out nicely. On the plate you see, there’s only 1 layer of epoxy. And I rubb this over, one more layer will be added and it’s finished.

And who was it that said is was very hard to use carbon fibre on corners?

The things I ordered to finish off the amp-box, are currently hanging somewhere over the ocean.

Then I put in another mill, and made a nice rounding on the upper side.

Then it was time for the professional work, and went about 4mm deeper with the right mill.

The grey disc with all the holes, I bought when I was in L.A.

Here your mill onto, and knock on the attached pin, in the center of your piece. So you can chose with diamter you delete. It's something really really simlple, but just so practical, and I wasn't able to find it here in Belgium.

 Here you see the little ring I need on the left side.

You can say....it looks much better then without the ring.

I did the same for the logo on the backside, just that's a bit smaller.

Here they are, Dumb & Dumber

On the backside, I milled it all a bit diagonal, cause I'm going to glue the carbon into the aluminum with 2 components glue

The carbon lay-ins are ready to get some layers of varnish. To become this result, I’ve been abrading for several hours, and I’m really pleased that’s behind me now.

About the emblems, I’m working on my own logo to add to that.

As you can see, the pedals are ready to get mounted in the car.

These are silver, and are underneath the varnish, so nothing can harm them there

The brake.

As you look closely on the bottomside of the carbon fibre, you’ll see there’s a lot of varnisch on there.

This varnisch is scratch-free, and is as solid as a rock. Time will tell…

 The gas pedal.

And finally, the complete set.

These set of pedals, I think, will need a yearly maintenance…

My carbon fibre stock is empty for the moment, but next week 10m² will be delivered… so up to the next!

Meanwhile, I totally finished the CF logo’s. Here the show pictures.

For me, they worked out a 100%, and again, I’ve got something original.