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The doorpanels i using are secondhanded. So the car remains complete, and I doesn't have to drive without panels all winter. Demounted some stuff.
Started taking off the leather. awefull job
The 16cm FOCAL speaker is taking approximately the same place where the original speak is. In the meanwhile , I let the rings mild nicely.
I milded some MDF wooden rings to tighten on the doorpanel.
To lock the speakers tight I made a extra alu plate of 6mm thick. Here I can use the screws that came with the FOCALS. These are special screws that click-in the grill.
This is an seperate little cap that goes on top. This model will be editted more. This will come nice when it's finished.
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Designerdepartment going at full speed Worked on the ring where the speaker goes in, more smooth now. Step by step, till it workes out to something he likes;
On picture, maybe it doesn't look so good, but IRL it looks fine. The forms i made also come back in the original panel. So it's more styled this way.
Here a couple of pics of the original doorpanel, to compare more easy.
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And this is what it's going to be. The door, on the speaker, gained 2cm more to the inside of the car. This is what I had to do to get the speaker in there in a good way.
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The seperate polyester cap, that goes over the speaker, will come in silver, like the trim. This will contrast with the rest.
Picture with the grill.
If I look at this all, I think it doesn't contrast to much with the lines, shape of the original panel.
Has to be rubbed and finished some more. On the backside of the panel, maybe there will come a little light, that shines when the door is opened. Partially to fill up the big piece.
Posts: 19 | From: belgium | Registered: Jun 2008
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In the meanwhile I made a whole into the doors platework, behind the speaker. You can see the windowglider. Just nog touching the speaker.
Made some more parts, to fill up the other wholes.
On the background, there's a alu plate of 4mm thick. Very hard and strong. In the middle you can see 2 Carbonkevlar parts. I made em as thin als possible . On the foreground you see 4 little rings I made, to screw the doorpanel extra tight.
If you look to the second on the right, there's a little rubber he pasted on. On the place where he screwed it. This to prevent resonance.
On the picture you see a little pole picking out. That's MEGA IMPORTANT. Behind the speaker, there'll be another screw, so we can attach it even more in the middle. Posts: 19 | From: belgium | Registered: Jun 2008
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This won't be the end of the door. I has to make some tiny wholes airtight, but that won't go untill the has all the material to fill up the sound. All I makes, will be filled up with this material. What exactly I going to use, he's not sure. we'ill keep u informed.
As you can see, I putting a lot of work into all this. And more work is coming up so the sound won't be lost...
I think this is a type of work, that is underestimated be many people. But the work will pay of in the end, that's what we are sure of...
Posts: 19 | From: belgium | Registered: Jun 2008
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The bottomsides of the doorpanels will have to be done in CARBON FIBRE.
So a dificcult object to get in the Carbon fibre. But we must admit, it's done nicely.. Many time was put into preparation the prevent the CF - overlay to got wrong at any place.
This annoying little side was one of the many things that could go wrong.
Also, I was satisfied to get the little lamp in there. makes the piece a bit more interesting then one big lumb piece.
This is the ditch I disced into the panel. For those who don't get the picture. When it's all done, the upperside of the panel will be overlayed in leather. Then I needs a little space the get rid of the too much leather. To get a nicer finishing off
You see on this pic that everything at the bottom is in CF..
Now the big work is to get it all nice and flat. Put some more layers of epoxy on there till it's all nice and smooth. so, lots of work and patience...
Posts: 19 | From: belgium | Registered: Jun 2008
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This is the 3th layer of epoxy. Rubb it all down flat and equal everywhere, and then another 4th layer of epoxy. Some pics Posts: 19 | From: belgium | Registered: Jun 2008
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After firmly rubbin' the epoxy, I added another layer op expoxy. Maybe it's not so visible on the pic, but it's quit flat already. 4th layer of epoxy.
Now it's important to rub the last layer good. Start with an 800 and end with a 2000.
I also found the same black leather to cover the panel like the original one.
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In the meanwhile the doors are sprayed with matt varnish. For the most of you, we think, it'll be not so cool as normal varnish. But according to Rob was going to be TOO much, if you know what I means. The only thing I was afraid of, is that the weave of the carbon wont surface enought to see. but as you can see on the pics, that's not the case.
This is the leather, where I overlayed the upper part with. This is 100% the same material as the original panel. In the middle will come the original panel, covered in leather.
When I did all this, I just needed to adjust the polyester piece above the speaker a bit...for a perfect fit. This piece will get painted MATT silver like the original trims andso of the beemer.
According to me, I like the normal shiny varnish more, but this will look more calssy for an interior i guess.
The doors are covered with the Skai Leather. Really f**ng job to do. There was a layer mouse of 3mm on, and that's really different to work with then normal skai. But.... Difficult still goes ....
I thinks it was a good thing to spray the fiberglass ring above the speaker in silver, like the rest in the car. The piece needs to be sprayed again, cause to me, it' isn't done perfect...
Here you can watch the lines, nicely flowing in each other.
nice pic
When I mounted it all, It came to notice, the MATT CARBON looked really great, and still nicely noticable. Shiny varnish would be TOO shiny for this interior..
As you mentioned at the end of your thread, the matte finish on the carbon fiber looks great. I like the way that you integrated the new speakers so that they appear to have been factory items. The trim ring over the speakers came out clean and really accents the speaker installation with the silver paint.
An all around excellent fabrication, with some very good pictures and descriptions.
-------------------- Adam Morales 96 Impala SS custom show Car 08 Ford F-250 4x4 CC 04 Escalade Posts: 31 | From: houston,tx | Registered: Oct 2002
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The piece I wanted to cover in Carbonkevlar, I painted black, to be sure the layer underneath won't show. milled some rings to put the woofers in. Posts: 19 | From: belgium | Registered: Jun 2008
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Here a picture of the bottomside, where he made wholes , to let the sound flow outside.
Still some more polyester work to do. Did some preparation to stretch the cloth nicely. Posts: 19 | From: belgium | Registered: Jun 2008
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