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This is the place to get answers, opinions and everything you need related to your E46 (sedan, coupe, convertible and wagon) BMW!

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Old 07-01-2016, 06:24 AM   #1
BubbleGum
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So me and a friend started making e46 products...

Before I begin, I own an e46 m3 from 2003.

So here is the story of what happened... I bought a couple of FRP products from different distributors... The first was a CSL rear bootlid for my m3... and it was... how to put it... hidious. The fiberglass was of poor quality, the epoxy resin that was used started to deform at 50 degrees, which were achieved during the painting process... and what it looks like at the moment makes me want to cry.

Here you see how the epoxy resin deformed:



Here is the GAP which opened on the left... fitment = horrible



Here is how the keyhole is not the right size and the interior light on the trunklid is tilted to the right...



And all these are after a lot of modification to the trunklid was made to even make it fit in this awful way!


I also was about to invest in a carbon fiber roof and bonnet. A friend of mine had a bonnet from one of the most known companies on the planet (I will not specify names). And... it was heavier then the normal aluminium one... What we later realized was that the bonnet was not actually two sheets of carbon, it is made from Fiberglass and covered in carbon on both sides... Yes, the cover up was done very precisely, but the bonnet was purely cosmetic, and actually added 300 grams to the weight... A real CF bonnet should be about 30-40% lighter then stock.

I study architecture in Manchester and I have an idea as to how the different parts are made. Three months ago I came into contact with a guy in Bulgaria (yes I am from Bulgaria, and we are not "animals" contrary to popular belief, we are just normal human beings from a foreign country) who makes different CF and FIBERGLASS products... from prostetic legs to rocket-bunny widebodies, and the quality was amazing.

I have a huge understanding of aerodynamics, I have been researching the matter for years and read books and what not - I have been a car fan since I was born... literally the first object I grabbed in my hand were my father's car keys and the second was a pencil... so now I am starting to get into the car-aero design world, which is... well... logical...

And this is how it all started... So we started making molds and laying out pieces... Our goal is to make very high quality products, which increase the downforce AND decrease the drag coefficient of our vehicles. Our first product is now almost launched, e46 m3 front fenders.

The first prototypes are 1.7kg in weight from fiberglass and we expect 900 grams from the CF. The stock ones are about 5.8kg in weight. The holes are there to decrease the drag created by the wheels, and the downforce is increased by a minor percentage because of the air pressing down on the fender when escaping through the hole.

Here are some pics of the fenders from fiberglass
Painted:



Unpainted.



sorry for the comercial logos, I got this from our facebook page, hope it is not against forum rules...

These will be sold for about 150 euro per fender in Bulgaria which is about 127 GBP in England... I am gauging interest for such products.. Today we are starting a mold for a CF roof and CSL style trunklid. Down the line we will start making FUNCTIONAL diffusers and other bits and bobs.

So overall, I am just making stuff for my own car (hense I try to make the products as OEM-fitting as possible) and I am wondering if you guys are interested in such products .

EDITED****

Oh I almost forgot, this is what the m3 fenders should look like on normal e46 cars:





Stay Safe,
Antony

Last edited by BubbleGum; 07-01-2016 at 06:31 AM.
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Old 07-01-2016, 06:37 AM   #2
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I'd be potentially interested in a CSL boot for a sedan, though shipping from Bulgaria to Australia would destroy any chance of me doing that, and i'd end up buying local for $500 AUD.
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Old 07-01-2016, 06:53 AM   #3
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Very nice work.

I will say this though... Aero is not intuitive. Without a wind tunnel, any claims of improved aero is simply blue sky, unless perhaps you are Adrian Newey. The theory is sound though.
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Old 07-01-2016, 07:46 AM   #4
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Also, you're a little late to the party.
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Old 07-01-2016, 09:22 AM   #5
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Originally Posted by Geo31 View Post
Very nice work.

I will say this though... Aero is not intuitive. Without a wind tunnel, any claims of improved aero is simply blue sky, unless perhaps you are Adrian Newey. The theory is sound though.
Our widebody panels will be wind-tunnel tested. When we get to aero parts which need this sort of testing to be sure they work properly, we will print small 3d models and test in a simulated wind-tunnel where Drag coefficient will be calculated as well as air-stream directions, lift spots etc. etc.
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Old 07-01-2016, 09:33 AM   #6
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^Yeah I dunno. It's possible the net effect, if any, would result in higher overall drag as you might disrupt airflow down the side of the car causing turbulence inhibiting clean air separation at the rear. Not to mention you will probably create some really nice mud streaks on the side. Not sure though?? Lookin forward to your testing

If you really want to make an aero difference with the fenders, round off the edges where it meets the tires =p
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Old 07-01-2016, 09:45 AM   #7
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Subbed, I would be interested.
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Old 07-01-2016, 10:07 AM   #8
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Also, you're a little late to the party.

How so? Most of the aftermarket stuff is total garbage. Sounds like he wants to change that and make some quality stuff.
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Old 07-01-2016, 10:09 AM   #9
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Subbed, I would be interested.

What about stuff for a sedan?
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Old 07-01-2016, 10:29 AM   #10
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Interesting...wonder, how much it would be to ship these to the US.
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Old 07-01-2016, 10:55 AM   #11
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I would like to see more pictures from different angles.
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Old 07-01-2016, 02:33 PM   #12
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Quote:
Originally Posted by BubbleGum View Post
Our widebody panels will be wind-tunnel tested. When we get to aero parts which need this sort of testing to be sure they work properly, we will print small 3d models and test in a simulated wind-tunnel where Drag coefficient will be calculated as well as air-stream directions, lift spots etc. etc.
Very cool. Are you able to do CFD modeling?
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Old 07-01-2016, 02:36 PM   #13
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^Yeah I dunno. It's possible the net effect, if any, would result in higher overall drag as you might disrupt airflow down the side of the car causing turbulence inhibiting clean air separation at the rear. Not to mention you will probably create some really nice mud streaks on the side. Not sure though?? Lookin forward to your testing

If you really want to make an aero difference with the fenders, round off the edges where it meets the tires =p
I see what they are trying to accomplish. The inside of the front wheel well is a high pressure area. By venting this high pressure out of the wheel well it reduces lift (some would say creates downforce). I'm not sure that opening is large enough though, but one step at a time.

Definitely plenty of opportunity for all sorts of grime, but if one is playing in that game, they tend not to care as much.
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Old 07-01-2016, 09:00 PM   #14
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Also, you're a little late to the party.
Not at all. There's always room for competition (especially if the quality of his products are better!).

I wonder how much it would be to ship to the US?
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Old 07-01-2016, 10:42 PM   #15
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Got my attention. I'm interested in sedan products personally.
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Old 07-02-2016, 06:49 AM   #16
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What about stuff for a sedan?
If there is demand for such products, ofcourse! We are starting with coupe's but noone knows what may happen down the line .

Quote:
Originally Posted by zander271
Quote:
Originally Posted by Mango View Post
^Yeah I dunno. It's possible the net effect, if any, would result in higher overall drag as you might disrupt airflow down the side of the car causing turbulence inhibiting clean air separation at the rear. Not to mention you will probably create some really nice mud streaks on the side. Not sure though?? Lookin forward to your testing

If you really want to make an aero difference with the fenders, round off the edges where it meets the tires =p
I see what they are trying to accomplish. The inside of the front wheel well is a high pressure area. By venting this high pressure out of the wheel well it reduces lift (some would say creates downforce). I'm not sure that opening is large enough though, but one step at a time.

Definitely plenty of opportunity for all sorts of grime, but if one is playing in that game, they tend not to care as much.
He actually has a point, if the turn that the air has to make is not smooth enough, the airstreem will not continue down the side of the car... this is exactly what is taken into concideration, because if two airstreems colide excess drag is created... this is why the opening and turn is only 2.5 degrees which is optimal, since air can pass without a problem and still connect smoothly with the stream going by the side of the vehicle . If you research the Pagani Huayra Front flaps, the bad connection with air-streams makes them really unfunctional - they just create excess drag, but no stopping power, I think it was explained in a youtube video somewhere. All of this is taken into concideration, so have no worries!
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Old 07-15-2016, 06:28 AM   #17
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Okey boys, some news!

For those of you who do not know the story, I actually have an aquaintance with an e46 m3 CSL. Long story short we will have an exact copy of the CSL bootlid on the market with perfect fitment soon! We got the bootlid some days ago and work has already started as you will see:

CSL BOOT first batch, prepping, fixing, reinforcing!

What do I mean by that? Well the CSL boot is made from a fiberglass/magnesium composite because fiberglass deforms from changes of temperature. What we are planning to do is to reinforce the product at certain points with double carbon weave in order to mitigate this effect as much as possible. One of the places is where the rear strip is (the CSL has no rear strip, but you get the point, where the LED Number lights are) This will increase price a little, but I am in for quality...I just have a friend with a leaking trunk, which shrunk by 1cm on each side... and it is made by one of the companies which all forums state as having the best-fitment and highest-quality... again I will not specify names.

Here are some pics of the polished and pasted CSL BOOT which we are working on.






CARBON ROOF!

So for the carbon roof I have info. The price is almost certainly going to be about 600 GBP. The plans was for it to be less, but the GBP fell in value against the Bulgarian LEV in the last couple of weeks, and I cannot put a lower price. What is important is again quality.

We will soon have pics, but here is the process, so anyone interested knows why the price is such.

The roof is 2x2 carbon weave. The highest quality resin is used, for best results. The roof is made through vacuum infusion, which creates a material as good looking as wet carbon, but with the strength of dry carbon. No material is wasted, since about 99% of the material needed is used. Also because of the process of manufacturing the strength of the material is better then hand-layed pieces.

FROM THEN ON!

There is more, so when the product is dispatched, it is then sent ***1090;***1086; be polished. First a high-quality polish is applied. After that it is waited to dry out. It is then worked over with a machine which has a very soft sand-paper like head, and polishes the polish (I know its cofusing, but bare with me) in a circular motion. After that a second batch of polish is applied which is UV-REFLECTIVE. Why? Well if not, there is a chance for the resin to turn yellow due to changes in temperature, especially in hot summer days. This is why some carbon items start having a yellow fog on top if left unpainted, and the depth and beuty of the material is lost...

WINGS

Out wings are ready, but one of our mechanics has a sick baby and will not be able to work on them until the 24th. June. As soon as they are fitted to the car I will post pics and if they fit perfectly, (which they will, but still we want to test it first) I will put them out!

Soon I will upload more pics and more info. I will try to keep you guys more up to date, but the past several weeks were so busy, I didnt get a chance.

Thanks for the interest, and stay safe!
- Antony

Last edited by BubbleGum; 07-15-2016 at 07:16 AM.
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Old 07-18-2016, 04:55 AM   #18
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I don't even want to ask about shipping to Australia, or if you'll make csl boots for the sedans. Great work though!
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Old 02-11-2017, 10:53 AM   #19
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I've only just found this thread and would be very interested, but it seems to have stalled. Are there any updates? I am about to put two new wings on my 330ci and was thinking of attempting to cut and fit the M3 side grills but these could possibly be a better option. Someone is already producing an ME style wing but I can only find them as a 4 door option.



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Old 02-11-2017, 01:01 PM   #20
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I've only just found this thread and would be very interested, but it seems to have stalled. Are there any updates? I am about to put two new wings on my 330ci and was thinking of attempting to cut and fit the M3 side grills but these could possibly be a better option. Someone is already producing an ME style wing but I can only find them as a 4 door option.



You're never alone with a clone, E46 mobile app version 5.2.3 (build 21200006)
Hi mate,

Yes I went to cutters and the thread there was going well, bt got banned recently. This is our FB page - it has all the info you need, and you can chat with me there as well

https://www.facebook.com/StreamlineAero/

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