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Focal Beryllium BMW


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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: September 14, 2009 at 1:31 PM / IP Logged Link to Post Post Reply Quote robolop

This will be the front of the amplifierbox. First I made a model in 5mm thick MDF.

Focal Beryllium BMW - Page 7 -- posted image.
Focal Beryllium BMW - Page 7 -- posted image.
Drawed it out on the aluminum of 10mm, and saw into it.

Focal Beryllium BMW - Page 7 -- posted image.

Taped the MDF plat onto it, and tomorrow, it’s mill-time

Focal Beryllium BMW - Page 7 -- posted image.

In the meanwhile I’m baking some carbon cookies in the oven.

The alu piece that will come onto the front of the box, is finished!

Cut out the wholes with the uppermill.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

This time I tried GT7 as lubricant, and I must say I’m very satisfied about this product!

Focal Beryllium BMW - Page 7 -- posted image.

Here I grabbed out some more mm’s between the wholes

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

This is the back side. You can see I grabbed out some more mm’s over the entire surface.

Focal Beryllium BMW - Page 7 -- posted image.

Here in will come a carbon piece, with my logo on it.

Once finished, I spent a big amount of time rubbing it all down.

Focal Beryllium BMW - Page 7 -- posted image.

Afterwards, held the piece under the polish-brush so it shines a bit

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

The small piece of carbon fibre, that’ll come on the back, is baking as we speak.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: September 22, 2009 at 11:40 AM / IP Logged Link to Post Post Reply Quote robolop

The cover of the amplifier got a total of 6 layers of varnish. I also used new epoxy, wich I find not so good.

There came a lot of little holes in the carbon fiber.
Cause there is so much varnish, I had to rubb it all flat and equal with the
block.
 Here you can see how much is really on there.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

After some firmly rubbing with a 2000, I started on the aluminum.

Cause of the rubbing, it got mat here and there.
Had to do this by hand, and used some UNIPOL for this.

Focal Beryllium BMW - Page 7 -- posted image.

Offcourse, the result here is not what it was before.

Using a machine would made this 10 times better.

After this I polished the carbon fibre.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Finally, the final result of this piece.

Focal Beryllium BMW - Page 7 -- posted image.

The hard part of this piece is that the transition needed to be descent, and it came out well.

Focal Beryllium BMW - Page 7 -- posted image.

Mounted the rings again.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

For those who think this is done… you can forget it.

Before I began covering the alu plate with carbon fibre, I mesured it.
The alu plate was 8.2mm thick. Now with the carbon layer on it’s 9.7mm thick.
That means that everything came up 1.5mm…So the plexi won’t fit that nice anymore.So I have to shorten the rings/toggles about 1.5mm

fabilichus 
Member - Posts: 1
Member spacespace
Joined: September 24, 2009
Location: Norway
Posted: September 24, 2009 at 7:49 PM / IP Logged Link to Post Post Reply Quote fabilichus
I have to give u alot of credit. The work u have done looks amazing !
I wish im gonna get the skills to make something half as nice as u did.
Question,
How do you get carbonfiber so shiny ?
Could u maybe make alittle how to on that ?
My Porsche 944 im not making alof of monney so it take some time for me to build it up realy nice and gonna be a show car in the end.
robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: September 28, 2009 at 5:08 AM / IP Logged Link to Post Post Reply Quote robolop

I got the chance to finish the aluminum sides of the amplifier-box.

You’ll see that I made the same wholes into the upperside, like there are in the toggles where the plexi is on.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

It’ll look like this on the outerside.

Focal Beryllium BMW - Page 7 -- posted image.

Here it’s mounted on to the box. You can see I put some fine gauze on the top. Later I’ll explane why I did this.

Behind the 5 wholes in the bottom there’s a piece of carbonkevlar.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: October 15, 2009 at 12:54 PM / IP Logged Link to Post Post Reply Quote robolop

Here some pics of the aluminum toggles I made.

These come on the Left en Right of the amplifier, and serve to tighten the plexi pieces on the sides.

Remember this?

Focal Beryllium BMW - Page 7 -- posted image.

These two won’t be visible.

 Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Of these, you’ll only see the upperside. You can also see I screwed a little piece of MDF on the inside.

That’s were the plexi will lay on to.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

This will get into the back. Again, you will only see the upperside.

Also you can see I knocked in an aluminum nail.

This will come between the plexi, a little hard to explain really.

But you’ll see what I’m trying to say.

 

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

In total, I had a lot of work making this, specially trying to fit and finish it in a descent way.

Getting into the trunk 20x a day, for messuring and trying. I’m going to be so happy when the amplifierbox is finished.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October 26, 2008
Posted: October 15, 2009 at 12:56 PM / IP Logged Link to Post Post Reply Quote robolop

This part will get underneath the amplifier.

On the bottom there’s a mirror of 4mm thick. The meaning is that you can look into the amplifier through the mirror, when the amplifier gets up.

Don’t forget I’m going to open the amplifier so you can see all of it’s components. Here a picture of how I pictured it before….

 

Focal Beryllium BMW - Page 7 -- posted image.
Focal Beryllium BMW - Page 7 -- posted image.
This is the plate, finished.
Focal Beryllium BMW - Page 7 -- posted image.
The sides will get on the same level/height as those from the amplifier.

Focal Beryllium BMW - Page 7 -- posted image.

Focal Beryllium BMW - Page 7 -- posted image.

The upperside  I polished, and the sides are brushed aluminum.

Focal Beryllium BMW - Page 7 -- posted image.
Here you can see I planned a little grill in there. This is the inside, where you won’t see anything.
Focal Beryllium BMW - Page 7 -- posted image.

asquarecan 
Copper - Posts: 64
Copper spacespace
Joined: November 25, 2008
Location: Oregon, United States
Posted: October 20, 2009 at 10:22 PM / IP Logged Link to Post Post Reply Quote asquarecan
Hands down some if not the most impressive work I have ever seen!
If you are located anywhere on the west coast I would love to see this thing in person!
Great work!
Keith
KarTuneMan 
Platinum - Posts: 7,056
Platinum spaceThis member has made a donation to the12volt.com. Click here for more info.spaceThis member consistently provides reliable informationspace
Joined: December 14, 2004
Location: Isle Of Man
Posted: October 24, 2009 at 10:19 AM / IP Logged Link to Post Post Reply Quote KarTuneMan

fabilichus wrote:
I have to give u alot of credit. The work u have done looks amazing !
I wish im gonna get the skills to make something half as nice as u did.
Question,
How do you get carbonfiber so shiny ?
Could u maybe make alittle how to on that ?

You won't get any answer to your question.... I tried a page or so back to ask a question as well.... no reply.

j.reed 
Copper - Posts: 716
Copper spacespace
Joined: January 05, 2009
Location: Arkansas, United States
Posted: October 30, 2009 at 5:57 PM / IP Logged Link to Post Post Reply Quote j.reed
KarTuneMan wrote:

fabilichus wrote:
I have to give u alot of credit. The work u have done looks amazing !
I wish im gonna get the skills to make something half as nice as u did.
Question,
How do you get carbonfiber so shiny ?
Could u maybe make alittle how to on that ?

You won't get any answer to your question.... I tried a page or so back to ask a question as well.... no reply.

From the looks of his 70+ posts all have been of posting pics with a little description and nothing more. I'm with you guys this is a simply amazing install. But i would not expect anything other than more posts of pics. Sucks too because there is a lot that could be learned from an installer of this level.
Focal Beryllium BMW - Page 7 -- posted image.
i am an idiot 
Platinum - Posts: 13,287
Platinum spaceThis member consistently provides reliable informationspace
Joined: September 21, 2006
Location: Louisiana, United States
Posted: October 30, 2009 at 6:52 PM / IP Logged Link to Post Post Reply Quote i am an idiot
The bottom cover of that amplifier is a critical part.  It is what holds the transistors firmly against the heat sink.  If you are leaving the cover off of the amp, you need to somehow secure the transistors to the heat sink. 
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