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bmw 540i fiberglass trunk


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blubalz 
Member - Posts: 8
Member spacespace
Joined: March 22, 2007
Location: United States
Posted: May 18, 2007 at 2:44 PM / IP Logged  

hello all,  im new to this site and kind new to custom car audio.   I work at a local audio/video place that does mostly home audio but a some car.  Ive done a couple custom jobs with former employees but this is my first that i have designed and built completely by myself.  the car is a 04 BMW 540i and i plan to go all out on this project.  im taking pics as i go along but im sure ill miss some steps.  but hope you guys enjoy.

blank canvas

bmw 540i fiberglass trunk -- posted image.

dynamated the wheel well.

bmw 540i fiberglass trunk -- posted image.

the customer had a custom system in his last car and decided that he wanted to use the same sub box.  it was in a is300 so i ended up just cutting the top off the box and reusing just the top and making a new bottom.

bmw 540i fiberglass trunk -- posted image.

i know its not ver pretty but this is the bottom i ended up building for it.  i couldnt nail it all the way around becaues of the way the top was built so i used bracket to help hold it together and then fiberglassed around the edge.  i also had to make a cut out so the sub would clear the box and fiberglassed that up.

bmw 540i fiberglass trunk -- posted image.

the rear speaker came with there own little pods from the factory so i decided to use them with the new jla xr5.25's

bmw 540i fiberglass trunk -- posted image.

the magnet on the jl speaker were alot bigger then the OEM speaker so i had to cut a hole in the pods so the speaker could sit flush at the top.

bmw 540i fiberglass trunk -- posted image.

then i glassed them to reseal them.

bmw 540i fiberglass trunk -- posted image.

added a little dynamat and mounted the speakers in the pods

bmw 540i fiberglass trunk -- posted image.

blubalz 
Member - Posts: 8
Member spacespace
Joined: March 22, 2007
Location: United States
Posted: May 18, 2007 at 3:05 PM / IP Logged  

capacitor mock up location

bmw 540i fiberglass trunk -- posted image.

begining of the amp rack

bmw 540i fiberglass trunk -- posted image.

it holds 2 ppi amps (not sure the model #'s, but they have been taken apart to display all the goodies)

bmw 540i fiberglass trunk -- posted image.

amps in there final location

bmw 540i fiberglass trunk -- posted image.

begining of the rear pannel, i used a little fiberglass to give it some shape

bmw 540i fiberglass trunk -- posted image.

how it looks on the amps

bmw 540i fiberglass trunk -- posted image.

capacitor mount after suede

bmw 540i fiberglass trunk -- posted image.

the front speakers finally came in they are JLA ZR525csi's

bmw 540i fiberglass trunk -- posted image.

starting the rear pannel

bmw 540i fiberglass trunk -- posted image.

getting the shape for the rear pannel

bmw 540i fiberglass trunk -- posted image.

adding ribs to get the shape i want

bmw 540i fiberglass trunk -- posted image.

bmw 540i fiberglass trunk -- posted image.

blubalz 
Member - Posts: 8
Member spacespace
Joined: March 22, 2007
Location: United States
Posted: May 18, 2007 at 3:07 PM / IP Logged  

ready to lay some fiberglass resin on the rear pannel.

bmw 540i fiberglass trunk -- posted image.

sanded it down and layer the first layer of bondo

bmw 540i fiberglass trunk -- posted image.

splhz 
Member - Posts: 2
Member spacespace
Joined: May 22, 2006
Location: United States
Posted: May 18, 2007 at 4:23 PM / IP Logged  
That's tight. The amp cover has a great shape.
If it's too loud your too old
auex 
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Joined: December 23, 2002
Location: Arizona, United States
Posted: May 18, 2007 at 11:00 PM / IP Logged  
Very nice. Not big on the showing the amp's guts, but that is a personal choice.
Is the vehicle yours or a customers?
Make sure the cap has enough extra wire length to provide access to the battery without having to undo alot to get to it.
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blubalz 
Member - Posts: 8
Member spacespace
Joined: March 22, 2007
Location: United States
Posted: May 19, 2007 at 2:45 PM / IP Logged  

auex wrote:
Very nice. Not big on the showing the amp's guts, but that is a personal choice.
Is the vehicle yours or a customers?
Make sure the cap has enough extra wire length to provide access to the battery without having to undo alot to get to it.

its a customers car, 

and im not sure what you mean,  the power wire is already hooked to the batt. and the fuse holder is on the side of the capacitor box.  i actually took the capacitor apart and extended the terminals using backstraps so the wire only needs to reach the bottom of the capacitor box.   heres a pic if i dont make sence.

bmw 540i fiberglass trunk -- posted image.

rawcustumz 
Member - Posts: 46
Member spacespace
Joined: March 27, 2007
Location: United States
Posted: May 22, 2007 at 12:29 PM / IP Logged  

Thats going to look awesome.

Is the whole thing going to be wrapped in seude?
Later
Bernie

Bernie
MECP Certified
64 Impala Wagon
2007 Camry LE
StealthEs 
Copper - Posts: 326
Copper spacespace
Joined: September 04, 2003
Location: New Jersey, United States
Posted: June 02, 2007 at 7:25 PM / IP Logged  
Very nice, cant wait to see the finished pic's.
Cris
truecustoms 
Member - Posts: 3
Member spacespace
Joined: October 29, 2006
Location: United States
Posted: June 05, 2007 at 7:37 PM / IP Logged  
That looks great man, have you ever been over to fiberglassforums.com? Its a great site if you're in to glassing.
"One machine can do the work of fifty ordinary men, but no machine can do the work of one extraordinary man"
-Elbert Hubbard
blubalz 
Member - Posts: 8
Member spacespace
Joined: March 22, 2007
Location: United States
Posted: June 06, 2007 at 4:23 PM / IP Logged  

thanks everyone for the coments,  the original plan was to wrap everything in black vinyl and have black suede accents in the windows.  but i think the customer wants to have it painted now so as of now thats what im going with.   but here are some updated pics.

i toyed with a couple ideas for the crossover location and mount but this is what i ended up doing.

bmw 540i fiberglass trunk -- posted image.

after suede plexi and mounting the crossovers.

bmw 540i fiberglass trunk -- posted image.

this is the begining of the side pannel.  i made a cover for the crossover box and the other pieces are the main structre of the pannel and to get the shape and line i wanted.

bmw 540i fiberglass trunk -- posted image.

bmw 540i fiberglass trunk -- posted image.

bmw 540i fiberglass trunk -- posted image.

ready for some resin

bmw 540i fiberglass trunk -- posted image.

bmw 540i fiberglass trunk -- posted image.

bmw 540i fiberglass trunk -- posted image.

little insert for the top to fill in the whole i needed to have in order to make the pannel removable

bmw 540i fiberglass trunk -- posted image.

bmw 540i fiberglass trunk -- posted image.

bmw 540i fiberglass trunk -- posted image.

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