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Posted: March 08, 2010 at 4:13 PM / IP Logged
You know...I get compliments all the time that I am a great teacher and mentor, but everytime I check on this thread of this forum, I become a student all over again 
and happy to be one. Robolop, this breakdown of the project is extremely appreciated.
The level at which you are fabricating those pieces is well... something to aspire to. I am sure all us of continue to be impressed and await more updates and pictures. Credit, where credit is due.
I am curious, what is your primary language? I also speak more than just english too.I have not failed. I've just found 10,000 ways that won't work.
When you do not know what you are doing and what you are doing is the best -- that is inspiration.
and happy to be one. Robolop, this breakdown of the project is extremely appreciated.
The level at which you are fabricating those pieces is well... something to aspire to. I am sure all us of continue to be impressed and await more updates and pictures. Credit, where credit is due.
I am curious, what is your primary language? I also speak more than just english too.I have not failed. I've just found 10,000 ways that won't work.
When you do not know what you are doing and what you are doing is the best -- that is inspiration. 
Posted: October 02, 2010 at 12:32 PM / IP Logged
The end pipes didn't look like that when I ordered them on the internet.The thing I'm pointing at, should have been straight.
Then I also have a heat-shield to put on the back of the bumper.
I think you already know, I ordered some things for the amplifierbox. Cause these things still aren't delivered, I worked on some other things in the meanwhile.
Sitting still isn't my style :)The next update has nothing to do with car-hifi.When I bought the car 2 years ago, I already knew I was going to make this some day....Now I purchased a M-tech2 rear bumper with pdc.This is an original bumper from BMW itself, because I didn't want to get the same doodie, that I had with the front bumper.Once I received the bumper, I mounted it on, and it fitted perfectly!So I could paint it, and mount it on...but you know that's not my style :)I want the back of the car, look more like an M3. What the comments will be about this, I don't know, but I think it's the most beautiful rear of an E46.This also means I'm going for quad exhausts in the rear. This won't be easy...but yet, another challenge.
The original M3 doens't have a spare wheel in the back, but instead is the exhaust system.What maybe an even bigger challenge is that I'll try to make this work on the original exhaust.Because in Belgium, we have to go to a technical control every year with the car, I drove to the control-station and asked if this would be a problem.they told me that whatever goes behind the original exhaust is no problem, as long as they can messure the CO-output.After a long search on ebay, I purchased these pipes.The end pipes didn't look like that when I ordered them on the internet.The thing I'm pointing at, should have been straight.
You can see on the picture, it looks a bit curved.
I could do 2 things: Send them back, or tune it myself.... I did the last one I put in the disc an hour later after delivery .
This looked much better according to me. Now it's the art of making these things fit descently onto the exhaust system.
Because I knew that things of the exhaust will get very close to the rear bumper, I need to do something to keep the heat out of there. This is special material to go around the pipes, and can resist a temperature of 1200 degrees. Heath wrapping.
Then I also have a heat-shield to put on the back of the bumper.Posted: October 02, 2010 at 12:48 PM / IP Logged
Once I had this, I taped it all with paper-tape.
The hardest part of the exhausts is behind me now, and it worked out fine.
I put a lot of measure-work into it, but I'm proud to say that it's perfect onto the milimeter.On this picture, the end-pipes aren't mounted yet. Going to measure this again when it's all finished. Cause I hate it when mufflers come out to far.The original plastic piece on the bottom of the bumper....it already made a one way trip to the bin.It didn't fit one bit anymore, and off-course I want to change the model to something more beautiful.Here you can see the building of it.First I glued OAZE on the piece with hot glue. This material rubs like butter, and so I got a model faster.Once I had this, I taped it all with paper-tape.
Posted: October 02, 2010 at 12:49 PM / IP Logged
You see that the inner muffles are a bit higher then the outer ones. I already noticed this on several other cars too.This is one of my favourites, and I immediately noticed that the exhausts weren’t on 1 line.I never saw the car IRL, but I’m 200% sure that these are correctly placed too.
It just gives you a distorted image cause of the rounding of the bumper.I for one, will think 2 times before I say that mufflers are placed awry. 
To make the polyester piece the same LEFT as RIGHT, I made a mold.
Put some model into the polyester piece. Needs to be some more refining for the finishing off…
Cause I’m convinced that everything fits 100%, I discovered something.If you look at this picture, it seems something is not 100% right somewhere.You see that the inner muffles are a bit higher then the outer ones. I already noticed this on several other cars too.This is one of my favourites, and I immediately noticed that the exhausts weren’t on 1 line.I never saw the car IRL, but I’m 200% sure that these are correctly placed too.It just gives you a distorted image cause of the rounding of the bumper.I for one, will think 2 times before I say that mufflers are placed awry.
I also tried to make some pictures, exactly in the middle of the rear, but that’s not so easy.
To make the polyester piece the same LEFT as RIGHT, I made a mold.
Sometimes it’s quite simple….when you know it
Posted: October 02, 2010 at 12:56 PM / IP Logged
Put on 4 layers of fiberglass cloth.
I want as little space as possible between there, but this is a bit TOO small. A child knows this will rattle after 5 kilometers.So I took a little slath of 6 mm, and drew it out nicely onto the piece.
This piece will connect nicely onto the exhausts. First, I taped the bumper.
Put on 4 layers of fiberglass cloth.
This will be the foundation for the piece.
I glued some MDF against this, and put some model into it.
Then I mounted it on the car, and you can see I'm working with great accuracy.
The space between the tubes and the piece is not more then 2 or 3 mm.I want as little space as possible between there, but this is a bit TOO small. A child knows this will rattle after 5 kilometers.So I took a little slath of 6 mm, and drew it out nicely onto the piece.
Then I defined the length of the tubes.
You can see the line, that they'll come out about 10mm. The outer mufflers will come out a bit more.I determined this by the rounding of the bumper, when you look from above.
Then I looked with a sway-hook to get them diagonal aligned.
Here you can see how many space I have now. I sprayed the piece black to have a better view on it.
Now I'm about to saw the tubes on the good lenght, and spot-weld them on 4 places, then again, making sure they are still on the same line.
I made a mold of the black piece you see here. For the moment it is drying.Once this piece is ready, I'm putting it back in the mold.
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