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Old January 2nd, 2017, 21:21   #41
robolop
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Default Re: ROBolop Design (bmw e46)

I want to wish all of you a Happy New Year 2017.
Enjoy the creative process of making beautiful things.
And may most of your dreams come true ... I said most, not all, because life gets so boring if we don't have anything to dream about anymore.

This morning there was a strange person on my table.

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Old January 3rd, 2017, 21:37   #42
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Default Re: ROBolop Design (bmw e46)

Happy new year!
Looking forward to future updates!
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Old January 13th, 2017, 12:42   #43
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As you may have already noticed, I’ve posted nothing last months. About the doors I was making,there has been a drastic change.
After that I put the doors on a strict diet, they were still going to too heavy for me. I’ve put a really big amount of work in them the last couple of months, but hey…the world didn’t end.
The only thing I know is that again, I learned a lot about milling.
I am now working on making something totally different. In terms of weight, this is much easier because I do not go play in a closed casket..
The design will be totally different!
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Old January 14th, 2017, 19:11   #44
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Default Re: ROBolop Design (bmw e46)

Sounds interesting - tuned in to see where you go with this, cheers.
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Old January 16th, 2017, 20:45   #45
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Default Re: ROBolop Design (bmw e46)

This is the part where the Focal subs will get in.

It contains 3 layers of MDF.
The upper part is the part where the speakers will be mounted.
In the middle is an outer ring. These 2 are nicely rounded and will be glued togehter later on.
Underneath there’s a little sloth of 4mm of MDF which will be placed between the outer ring and the spakers.
Later more about this…









Because I’m not a partisan of tightening speakers in mdf, so I milled some Volkern (trespa) rings on the back.
I glued these on the mdf. So I can mount the speakers firmly without worrying the screw will loosen.




This plate of 8mm thick is a mold I’ve milled. Later more about this.



You can see that this sloth will be at the back.





In the meanwhile I’ve already finished some things on the 2 doors, so updates will follow shortly
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Old January 17th, 2017, 11:35   #46
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Default Re: ROBolop Design (bmw e46)

That looks positively spot on mate.
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Old January 19th, 2017, 13:42   #47
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Default Re: ROBolop Design (bmw e46)

These are about all the parts I have ready for the doors. This is from the left, and fort he right, everything else is also ready.




Because the part of the speaker will “float” against the doorpanel, I milled a 8mm thick plexiglass



On the inside of the plexi I’m going to paste a orange led strip
Once the interior lighting is on, everything will glow up nicely through the plexi



This will beo ne entire part, mounted against the original door.

.

Here you can see the plexi





The MDF around the spakers, will be covered in a layer of carbon fiber. But this shape needs to have some roundings before I start.





Here you can also see I made a little bin.



Then I made a piece of polyester to give it a nice finsih.



I remounted the basereflex. It won’t be functional anymore, but I thought I put a bit too much work into it to throw it in the bin.


Al these things will be screwed and glued on to the door until it’s one entire part.
Once this is dry, all the holes from the crews will be covered up. And then filler will come over.
I’ve already done this with the right door, and it looks pretty good I must say.
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Old January 19th, 2017, 14:09   #48
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Default Re: ROBolop Design (bmw e46)

Cannot wait to see the outcome of these doors mate.
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Old January 21st, 2017, 22:55   #49
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Default Re: ROBolop Design (bmw e46)

Thats lovely!! Keep it up!
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Old February 5th, 2017, 13:32   #50
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Default Re: ROBolop Design (bmw e46)

Now I have most of the parts ready of those 2 doors, I glued and screwed it to the original panel.
You can see I didn’t mind one or two screws less



Once this was done, I’ve managed to work out evertything it looks like one big part.



In the meanwhile the BMW artificial leather had been delivered and I covered the 2 speaker-panles. This needed to be done so the I could adjust the little front-panels for that.

On this one you can see the top one is ready. The meaning is that there’ll be a nice round edge around the speakers and the outside. This is a time consuming job. Onderneath you can see the plate under construction.
The first time putting filler with a rubber flap and moddelling it.
Here you see I just did some on my finger. It’s sometimes the easiest way to get a perfect rounding. Sometimes the easiest way is the dirtiest



Once this was all done, I needed to do the same around the speakers.
I’ve already done this several times, so I knew that if I demounted the ring to sand the filler, the edge on top will break off.
So I used some roundells to put under the ring, each 2mm thick. So everyting is a little bit higher. When something breaks off, I still have filler enough, and I don’t need to do it all again.
Wisdom comes through the years.



Putting filler and sanding






Making the roundings of these 2 plates I’ve been busy for 6 hours. I could have made these just flat, but…..you know.

Here the backside of the little bin. Cause I don’t want any stuff in my car, nothing will ever be in this ones, but it looks so cool when you have it.



The backside of the plate I can screw off for upholstery

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