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Focal Beryllium BMW


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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 1:51 PM / IP Logged Link to Post Post Reply Quote robolop

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.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Here you can see how it should like like when it is finished.
as i've said before: on the frontside of the crossovertray.
Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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.
Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.
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.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.

This will be used as a mould.

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

Focal Beryllium BMW - Page 4 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 1:52 PM / IP Logged Link to Post Post Reply Quote robolop

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.
Focal Beryllium BMW - Page 4 -- posted image.

I continued taking the piece out of the mould.

I had to clean it up a bit.
Focal Beryllium BMW - Page 4 -- posted image.
With an electrical saw i was able to remove the biggest pieces.
Focal Beryllium BMW - Page 4 -- posted image.
So now you see why i made the 2 holes in the board. Much easier to saw!
The rest was taken out by hand.

Focal Beryllium BMW - Page 4 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 1:53 PM / IP Logged Link to Post Post Reply Quote robolop

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.

Focal Beryllium BMW - Page 4 -- posted image.

Time to use my GIANT sandingtool.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.
This is how everything should look like in the end.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Plexy mounted.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 1:55 PM / IP Logged Link to Post Post Reply Quote robolop

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.
Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Afterwards i've filled it up with poly.

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

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Here you can see the crossovertray while opening.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 1:57 PM / IP Logged Link to Post Post Reply Quote robolop

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.
Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.

On this picture you can see that it fits perfectly.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Then i've sanded the carbon frames and prepared them to get painted.

Focal Beryllium BMW - Page 4 -- posted image.

The inner rail is mounted a bit lower than the rest. I'm going to fix everything with TEC7.
Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 1:58 PM / IP Logged Link to Post Post Reply Quote robolop

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

The carbon is already covered with epoxy.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Clearcoated.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 1:59 PM / IP Logged Link to Post Post Reply Quote robolop

This is what will be mounted inside of the crossovertray.

It will be covered with carbon.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

The inside of the crossovertray is also covered in carbon .

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 2:03 PM / IP Logged Link to Post Post Reply Quote robolop

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.

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.

Focal Beryllium BMW - Page 4 -- posted image.

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.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Afterwards it all got polished.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
The kopper connectors have been sanded and clearcoated
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 2:08 PM / IP Logged Link to Post Post Reply Quote robolop

he you can see everything mounted in the car

this is the frontpiece of the crossovertray.
Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

the carbonworks...

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

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

I've made everything stronger
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
here you can see how everything works

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.
Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: August†21, 2009 at 2:13 PM / IP Logged Link to Post Post Reply Quote robolop

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

Meanwhile the bumper has been painted and Iím 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.
Focal Beryllium BMW - Page 4 -- posted image.
The alu plate where the copper gets through got chromed. So keeping it clean, wonít be an issue any more
Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

This is the result of lots of thinking.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Here the carbonkevlar and the plexy cupola is on.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Almost like fishes in a goblet

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Focal Beryllium BMW - Page 4 -- posted image.

Iím 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, donít you think?

Focal Beryllium BMW - Page 4 -- posted image.

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