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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 2:17 PM / IP Logged Link to Post Post Reply Quote robolop

I fastened he plexi copula in the meanwhile. In the plate where the screws rest, I milled a groove of 1 centimeter and filled it up with polyester.

After that I wormed some screw-thread in, to turn the screws in.
I had some pictures of that, but can’t seem to find them anymore. You can also see I pasted a selfsticking strip on there, so the copula stretched itself up, and makes it airtight.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

On the bottomside, I mounted a led-strip.

It’s a strip where the leds are poured into some kind of silicone. I bought this specially because I didn’t want it to snap  from  the pressure of the speakers

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.
These are some pictures I took in daylight

Focal Beryllium BMW - Page 5 -- posted image.

Here you can see the blue light, shining through the speakers, find it kinda cool

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Pictures in the dark.

Focal Beryllium BMW - Page 5 -- posted image.

Look what a reflection I get with all that varnish

Focal Beryllium BMW - Page 5 -- posted image.

These are some pictures where I put on some more light from above.

It will look like this when everything is mounted in the trunk.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

This is about it for the sub-box, yep, eventually, there has come and end to it

For myself, I’m really satisfied with the result, it even looks better then I imagined.
All the hours of work it absorbed …well, I already forgot.

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

The kidneys and the windowsmoldings are painted deep gloss black and mounted back on.

It won’t be everybody’s taste, but it works for me.

Focal Beryllium BMW - Page 5 -- posted image.

I don’t find the front that busy anymore

Focal Beryllium BMW - Page 5 -- posted image.
Focal Beryllium BMW - Page 5 -- posted image.
The windowmoldings on the side please me also more that I tought.
Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Some buddy’s asked me if I had darkened my windows…lol

They just show more dark then before, cause of the dark moldings.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

The car will stay like this , this season, it lookes fine for me.

Next winter I’m getting another rear bumper, with quad exhausts (like the M)
But now, I’m focusing on the ICE again.
Got some idea’s in my head, that’ll involve lots of work.

This is the plexi where it’s all about

I tightened this with 6 screws

Focal Beryllium BMW - Page 5 -- posted image.

Turned it all over and drew out the whole.

Through this whole you’ll see the amplifier on the inner side.

Focal Beryllium BMW - Page 5 -- posted image.

Drew out how I wanted the slots.

Focal Beryllium BMW - Page 5 -- posted image.

On this wooden plate I’m going to mill the plexi. First I made a slot here and there, so the mill won’t touch the wood. So I have a nice bottom to work on the plexi.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Before I begun, I messured out how many mm I had to span/yoke the slath, to glide next to with the mill.

Focal Beryllium BMW - Page 5 -- posted image.

Once this was done, the muppet-show could begin

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Nr1 is done, 3 more to go

Focal Beryllium BMW - Page 5 -- posted image.

When you look closely, you see I hit a little slath in the 2nd slot on the bottom.

I did this each time, so my plexi was always straight up when I was making the whole.

Focal Beryllium BMW - Page 5 -- posted image.

Done with milling, thank you lord I still have all my fingers.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Now the time has come to rubb and polish all of this nice and equally.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 21, 2009 at 2:22 PM / IP Logged Link to Post Post Reply Quote robolop

I’ve managed to continue on the plexi plate. Before I started rubbing, I tape it.

When you even LOOK wrong at plexiglass, you’ve got scratches, so being carefull is the question

Focal Beryllium BMW - Page 5 -- posted image.

So I started searching around for a fine rubbing material, and this was the best tool I got…and the easiest.

On the left just a ordinary aluminum plate to do the straight sides and lines, on the right a thick pen with around it my rubbing paper, for the curvy parts.

Focal Beryllium BMW - Page 5 -- posted image.

To do this, it took me 5 hours to polisch and rubb it all.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

The bottom where the plexi is screwed on to. The black you see is self-adheside vilt. I used this so I couldn’t make any scratches.

Focal Beryllium BMW - Page 5 -- posted image.

Inside of the ….’tank’ ‘box’ ?

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

This thing will be my mold for bending the plexiglass. The cover, that comes onto the top of the amplifier, will be round, as you can see.

The MDF (wooden) chassis:

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

I covered this with an aluminum plate of 0.5 mm thick, so I got a nice rounding.
Also, I made it more round as it finally has to come.
Once the plexi is cooled off, it always brends a bit more straight again.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Hopefully this works, cause just on the mold, I had some reasonable work.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 21, 2009 at 2:24 PM / IP Logged Link to Post Post Reply Quote robolop

This is the plexi I folded/bended with the paintstripper.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

As you can see, I didn’t go as well as planned.

The problem with the paint stripper is that I doens’t heat everything at the same time.
This wasn’t the case with the plexi of the filtercase.
Just needed one fold there, so just had to heaten only one line.
With this big piece, the plexi glass cools don’t too fast, and the temperature isn’t the same everywhere.
So actually, a piece like that, has be heated in an oven between 120 – 150 degrees Celcius.
Since I didn’t find an oven in that couple of days, I bought me a plexi plate.
You can’t boggle for long now, do we…
I think this looks mucht better already.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

These two pieces come on the sides. So you’ll get the idea it’s one big, entire piece.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

I worked some more on the two aluminum sides of the amplifier box, with the uppermill.

First tightened those thick plates.

Focal Beryllium BMW - Page 5 -- posted image.

Planted the mill.
The meaning here was to remove some millimeters, cause there has to come a carbonkevlar plate.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

These are the sides that come on the outerside, to service as coverplate.

Focal Beryllium BMW - Page 5 -- posted image.

You can see on the holes, that the design here will be the same as the sides of the filtercase.I also milled away a couple of mm’s here.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Abraded it all firmly so I could polish the aluminum.

Focal Beryllium BMW - Page 5 -- posted image.

Here an example what it will look like

Focal Beryllium BMW - Page 5 -- posted image.

Have to give a rounding on these 2 plates, cause the plexi comes in between.

Of these pieces of aluminum I’m going to make a frame, where the plexi will rest in.

Focal Beryllium BMW - Page 5 -- posted image.

The big plate i 8mm thick

The 8 other ones are 6mm thick

Focal Beryllium BMW - Page 5 -- posted image.

This isn’t going to be all, I’m going to use some other aluminum profiles also, but haven’t got the mesurement of those ones.

Many and many hours of millwork will get into this, but when it all works out like I have it in my head, it’ll be pretty cool.

Oh yeah, I’ll use some carbon fibre here too, but thought you gus will guessed that already..

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 21, 2009 at 2:25 PM / IP Logged Link to Post Post Reply Quote robolop

I made 4 aluminum supports of 8mm thick.

These have the same rounding as the plexi.
First, I made a mold out of mdf. After that, I drawed out the aluminum piece, and sawed it out.
after that, with double sided tape, I sticked it all together.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Once this was done, I held it all to the copy-mill

Focal Beryllium BMW - Page 5 -- posted image.

Here a picture of how it will look.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

The next step was to “modify” the supports, cause it looks a bit simple like this.

The lower plate is the model I made.
It’s only 4mm thick.

Focal Beryllium BMW - Page 5 -- posted image.

In the piece I needed, I got rid off the aluminum, and sticked it all together again, and then got the mill back in there.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Looks way cooler according to me.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

The other 3 will suffer the same cause.

The pattern looks good, but the support still doens’t look the way I wanted too…So I guess I’m going to modify this some more.

Too some issues I didn't get the chance to do much on the ICE.

But now , a 'little' update.The 4 toggles where the plexi will lay on to are finished

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

The alu-plate of 8mm where the toggles will get onto.

Focal Beryllium BMW - Page 5 -- posted image.

Offcourse, some holes were needed here, otherwise you wouldn't be able to see the amplifier.This is the mold I made of 4mm thick MDF wood.

Focal Beryllium BMW - Page 5 -- posted image.

Layed this on the aluminum and drawed it out

Focal Beryllium BMW - Page 5 -- posted image.

Then, I drilled some holes, and sawed it all out with the electric jigsaw

Focal Beryllium BMW - Page 5 -- posted image.

Pasted the MDF mold on to it.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Then I mounted my upper-mill once again under the table to do some dangerous stuff :)

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Here the result

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Then I 'modified' the outer toggles.

Because a M6 bar with screw-thread will get into this one, I had to drill the hole much bigger, so the nut is sunk into it all.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Made it big enough so it would be possible to get a 10 on there as well

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

In all toggles I tapped a screw-thread of M5, to fasten them at the bottom

Focal Beryllium BMW - Page 5 -- posted image.

Once I had all of this, I could begin the mounting.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

The front and back of the thick plate, I milled in a gap whereto I screwed a big L onto.SO I have a nice finishing touch, and the plexi is tense.

Focal Beryllium BMW - Page 5 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 21, 2009 at 2:27 PM / IP Logged Link to Post Post Reply Quote robolop

Here are some aluminum parts I'm going to work with in the cover.

The 9 tubes you see on the fore-ground are from anodised aluminum.
On the backside you see 3 threadstaff of m6

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Here you see why I had to sink in the m6 screws.

Focal Beryllium BMW - Page 5 -- posted image.

A picture here from the complete part, with the plexi on.I will have to screw this tight still, so I stays right where it needs to be.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

The whole part makes me feel that the amplifier is behind bars, in jail.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

As you may see, on the left, and on the right, I have a gap of about 4cm for the cables (for the amp)

As you may know by now, I'm not a fan of cables in an install, so...
I made 2 pieces of carbon fibre for the sides, so the connections will not be visible.
First, I made a fiberglass mold of the amplifier.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Once this was ready, I rubbed out the lines of the tape.

Focal Beryllium BMW - Page 5 -- posted image.

finished, so put on a layer of carbon in there.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

By doing this , I learned something really stupid.

Because I never took a mold of thins I make, I don't have the necessary products here to do that.

So I solved this on a idiotic way, really.
I just bought some plastic tape of 50cm? 50mmwss wide.
Taped it in the mold, and rubbed it in with polishing wax.
here you see the tape.

Focal Beryllium BMW - Page 5 -- posted image.

So you see, somethings will go with simple methods.

After this all, I put in the disc in the carbon fibre, and rubbed the piece nice and straight with my giant abrading block.

Focal Beryllium BMW - Page 5 -- posted image.

This is what I needed!

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

To tighten these 2 pieces, I have to make some aluminum toggles on the amplifier, so they connect with the rest nicely.

The carbon plates still need some layers of epoxy.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 21, 2009 at 2:28 PM / IP Logged Link to Post Post Reply Quote robolop

If made 2 toggles to tighten the carbon pieces onto the amlpifier.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Here , everything is on the amplifier.

Focal Beryllium BMW - Page 5 -- posted image.

You can see I only put in 1 screw.

The carbon fibre sits in between the aluminum and the amplifier, tight as a rock.

Focal Beryllium BMW - Page 5 -- posted image.

When the cover is on, you aren’t gonna see that miserable screw anymore.

Focal Beryllium BMW - Page 5 -- posted image.

I also worked on the 2 sides of the amplifier-box.

I milled out as many aluminum as possible, where the cables will have to come.It will be tight, but we like it that way

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

On this aluminum slat, I'm going to mount 4 little vents who gives some extra cooling on the PPI.Cause the "feed" part of the amplifier is on the right side, I also did it on that side.The aluminum plate is 4cm high and the vents are 2.8cm big.

These 4 wholes, I drilled with a "step"drill

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Then I glued the slat on a piece of mdf, and made the wholes as big as the aluminum with the uppermill

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

Then I took the mill, to round up the frontside of the aluminum, and so it's all milled nicely.

Focal Beryllium BMW - Page 5 -- posted image.

Then I milled the backside of the slat diagonal

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

after that I, carefely, drilled the wholes, who will serve to tighten the vents.

I used some normal wood-screws fot that.

Focal Beryllium BMW - Page 5 -- posted image.

This is how it looks on the frontside.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

The meaning now is to polish that slat of aluminum, and put a layer of carbon fibre over that.Once this is all finished, I'm going to put in the uppermill again, to round up the frontside.

The meaning is that you'll see the aluminum that's rounded.
If this is possible, I'm not sure. HAven't done it myself either...but , there's a first time for everything!

deeg money 
Copper - Posts: 107
Copper spacespace
Joined: October 26, 2008
Location: Florida, United States
Posted: August 23, 2009 at 12:08 PM / IP Logged Link to Post Post Reply Quote deeg money

Robolop,

Where did you learn to do all of this. I would love to create something like this for my truck or at least learn to use alu like you do. I am gonna take a wide guess but Im guessing your not from the states? I was wondering what kind of milling tool you used so I can look for one to start fooling around with on some projects.

  Oh and by the way your car is looking awesome. The work you do is pretty amazing. How many hours have you put into this?? Have a good one man!

Deeg money
"If you cant be good, be good at it"
yimke 
Copper - Posts: 417
Copper spacespace
Joined: June 23, 2009
Location: Nebraska, United States
Posted: August 25, 2009 at 11:15 AM / IP Logged Link to Post Post Reply Quote yimke
Holy cow I think I just took in my total picture count for the week.
On a serious note though, good work.Focal Beryllium BMW - Page 5 -- posted image. Focal Beryllium BMW - Page 5 -- posted image. Focal Beryllium BMW - Page 5 -- posted image. Focal Beryllium BMW - Page 5 -- posted image. Focal Beryllium BMW - Page 5 -- posted image.
robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: August 27, 2009 at 3:17 AM / IP Logged Link to Post Post Reply Quote robolop

The aluminum slat where the vents are going into is firmly rubbed down.

Then I polished the roundings of the holes.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

This aluminum L-slat is to finish off the frontside of the amplifier..

Here you see I preserved it with a layer of carbon fibre.

Focal Beryllium BMW - Page 5 -- posted image.

Focal Beryllium BMW - Page 5 -- posted image.

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