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Ice Ice Polo Robolop Design


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robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:23 PM / IP Logged Link to Post Post Reply Quote robolop

Cause of the cold this week, I didnít manage to do much. Where Iím working at the moment, thereís no heating, and you can feel the cold cominí out of the ground. There are nicer days to work on an install.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

The 2 alu frames (for the glas to rest on) are finished. On the back of the subbox, where the hinge is placed, I had to weld an extra iron.

After that I drilled a LOOOOOOOOOOOOOOT of holes in the aluminium, and also in the iron and alu bar. After that I made some screw-thread in there so I could tighten it all nicely. Remember, the subbox needs to be 100% closed.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Once the holes were good, I taped the glass onto the aluminium.

I chose 2x4mm laminated glass. This is the same as the glass thatís in your front windshield of your car. I chose this because itís superstrong, be also, must it ever break, the shattered pieces wonít fall apart, due to the special film thatís in between.
You never know the glass will burst after my wife plants a bag of potatoes into the trunk, then it wonít be the end of the worldÖ just needs a new glass.

I glued the glass with black TEK7.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

I left this to dry for more than four days, and it still wasnít dry. Probably because itís cold and moist in my garage for the moment.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Then I worked on the connections of the woofers.

Here you can see the 8 alu tubes where the cable gets through. You can also see LED holders, and little O-rings.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

First of all, I glued the led holders into the alu tubes with 2 components-glue

Because my cable didnít got through anymore, I had to abrade the LED holders one by one till the cables got through again.
F*CKN JOB...

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Another doodiety job was that I had to sand down the inside of the holes, where the tubes glide through.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Once all this was done, I could place the tubes through the holes without scratching it.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

You can also see the O-rings I slipped over it, to get a nice finishing touch.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

With these connections I want to prove that it doesnít always have to be copper, and you can make nice things with normal stuff.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Here you see how the glass rests on the subbox, and how itís screwed. Offcourse Iím going to place rubber in between to get a more perfect seal.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

The glass on the amplifier part: This will be tightened with a couple of screws, so if I have to turn the EQ, itís just a matter of screwing some screws loose.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Another cool shot

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: December†22, 2012 at 7:24 PM / IP Logged Link to Post Post Reply Quote robolop

Exiting day today.

I mounted the box into the trunk. I used every inch possible in there, but I had a good feeling when I let the thing go up and down.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

I had to do a minor adjustment with the hammer. The box didnít go (only for a couple of mm) by the eyes on the back of the trunk

STOP- Hammertime! lol

You can see how close it all is.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

I also changed something on the hinge and now I need to finish it off.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

When the trunk is up to gain access to the spare wheel, I need to flatten out the back seat

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

I think the spare wheel is easy accessible, no?

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

robolop 
Copper - Posts: 157
Copper spacespace
Joined: October†26, 2008
Posted: February†17, 2013 at 10:50 AM / IP Logged Link to Post Post Reply Quote robolop

I managed to lift the box in the trunk, without using much force.

It lifts easy with only using a couple of fingers.

You can see how easy I managed to solve this.

I welded 2 springs together. I had to do this cause 1 long one, wasn't strong enough.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

I also used a steel cable of 3mm.

To tighten these, I used some ordinary luster-clamps.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

You can also see I mounted the springs on top of each other, otherwise there was no room.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

You can see on the length of the cable, I can still add more tension on it.

That I will do once it's all mounted, then I can do the fine tuning of it.

Here you can see how tight it all is next to the box, and what I mean with putting the springs on each other.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

The springs and the hinge, there's also some fine-tuning necessary. I have to sanded down, and spray it.

Around the springs I'm going to pull a tyre of a kidsbicycle, so that it can't vibrate.

The box is placed on 4 rubbers, also for the vibration. But I also had to make something to tighten the box on once it's closed.

I had to do this in a simple way, so that my wife didn't need to go throught a procedure of 10 things before getting to the spare wheel.

I've managed to solve this with only 1 inbus-screw

The shackle I made, is screwed in the trunk. You can also see a rubber cap on it.

Underneath I tapped some screwthread.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Then I made a little aluminium plate, and screwed it to the box.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

So when the box is closed, the plate comes directly on the shackle.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

I tuned this with another inbus-screw (M10).

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

And so you can screw it loose or tight with only 1 screw.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

Sometimes I wonder what the hell I'm doing with the bimmer.

When I was working on this thing, I ask myself why I'm not doing things more simple. No head-aches, and in a much faster pace.

Ice Ice Polo Robolop Design - Page 2 - Last Post -- posted image.

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