E46 BMW Social Directory E46 FAQ 3-Series Discussion Forums BMW Photo Gallery BMW 3-Series Technical Information E46 Fanatics - The Ultimate BMW Resource BMW Vendors General E46 Forum The Tire Rack's Tire Wheel Forum Forced Induction Forum The Off-Topic The E46 BMW Showroom For Sale, For Trade or Wanting to Buy

Welcome to the E46Fanatics forums. E46Fanatics is the premiere website for BMW 3 series owners around the world with interactive forums, a geographical enthusiast directory, photo galleries, and technical information for BMW enthusiasts.

You are currently viewing our boards as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!

If you have any problems with the registration process or your account login, please contact contact us.

Go Back   E46Fanatics > E46 BMW > The Showroom

The Showroom
This is the place to show off your BMW to other members of the community. Post pictures and videos of your car and the modifications you have done to it. If you need a picture of something on a coupe, sedan, convertible or touring you will probably find it here!

Reply
 
Thread Tools Search this Thread Rate Thread Display Modes
Old 06-26-2006, 11:28 AM   #1
LAFENGAS
www.thielstudios.com
 
LAFENGAS's Avatar
 
Join Date: Jan 2003
Location: West Palm Beach, FL
Posts: 1,333
My Ride: 330ci
Send a message via AIM to LAFENGAS
Arrow DIY Project: Front Bumper Fabrication, version 3.0 (CSL)

Okay...so my last bumper was an ///M3 bumper that I hacked up to fit my car and molded the ACS lip to it, ect. Anyway..after a year and half of abuse the ACS lip cracked pretty badly and other flaws that bother me. Bottom line, it was time for a change.

I liked the CSL bumper, but didn't care for the single duct and CSL V2's do nothing for me. so i decided to modify the CSL bumper to my liking.

Everything posted within this single post was done friday evening and saturday. I still have minor work to do, but this was the majority of my concerns.

1st. The Splitters were very weak looking. Holding them up to the light i could see right through them! Worried that I would crack them if i hit anything, now was as good a time as any to reinforce them:



So...i dipped into my ballistics kevlar supply (this isn't the aesthetic stuff)



Reinforced the backside of the splitters. The 'pointed' frontmost section has 7 layers of kevlar which is thicker than standard issued army helmets. It's not pretty stuff, but it works!

LAFENGAS is offline   Reply With Quote
Ads by Google

Guests, get your FREE E46Fanatics.com membership to remove this ad.
Old 06-26-2006, 11:28 AM   #2
LAFENGAS
www.thielstudios.com
 
LAFENGAS's Avatar
 
Join Date: Jan 2003
Location: West Palm Beach, FL
Posts: 1,333
My Ride: 330ci
Send a message via AIM to LAFENGAS
Next I started taking measurements for the duct so i could make an accurate mold and posistion it correctly. It's not simply just cutting a hole out. To do it correctly, the duct is angled slightly and has a taper to it.



I found a large yogurt container had a near pefect size. Taking my depth measurements i transfered them to the yogurt container to get the proper sizing and angle.



I then took an uncut yogurt container and poured plaster in to allow it to solidify an make a good sturdy mold. I used my vacuum bagging system to force the Carbon Fiber tightly around the yogurt container. If i didn't reinforce it, it would just colapse under the pressure. (this obviously wouldn't make a great mold)

This pic is fresh from the vacuum bag. There are several layers ontop of the carbon fiber. This process removes a lot of excess epoxy so you have a higher CF to Epoxy ratio which gives you a stronger lighter (not that it matters much for this) part. But i had to make sure the CF was pressed firmly against the mold to get a nice smooth shape on the inside of the new duct



Once all the garbage has been removed and the yogurt container pulled from the CF this is what it looks like:



Now I cut the CF to shape using the template i made earlier out of the other yogurt container. Putting the CF duct in the appoximate place on the bumper, i used more CF to build a flange around the duct. Doing this gives a more rigid part, more as well as surface area to bond the part to the bumper.




Now to cut the hole. I put a piece of paper over the OEM duct and traced it. Flipping the paper over gave me the mirror image i needed to be able to a hole in the proper shape and location on the opposite side.



Using a high strength 2-part epoxy to bond it in place. I left the hole slightly undersized so i would have material to play with once the duct was in a permanent location:



After some sanding and rounding the edges to match the otherside. notice the hole isn't a circle, but oblong. Not an easy hole to match and place correctly:



And the duct complete:


Still have more fabricating to do on other areas of the bumper, but I was happy that I got the process down well enough to complete in a short time. Started it Friday early evening and the duct was completed as shown on saturday, the next day.

I have more work to do and will update this as it's completed.

enjoy.

Last edited by LAFENGAS; 06-26-2006 at 11:32 AM.
LAFENGAS is offline   Reply With Quote
Old 06-26-2006, 11:33 AM   #3
eddiee46
Registered User
 
Join Date: Aug 2005
Location: at home
Posts: 1,943
My Ride: e46
wow, great amount of details....

subscribed...
__________________

a member of ....

eddiee46 is offline   Reply With Quote
Old 06-26-2006, 11:38 AM   #4
3TARD
Registered User
 
Join Date: Dec 2005
Location: providence
Posts: 592
My Ride: 2000 323Ci JET BLACK


You are the king of custom fabrication on this board; excellent work
__________________
3TARD is offline   Reply With Quote
Old 06-26-2006, 11:44 AM   #5
S4izzle
Banned
 
Join Date: May 2003
Location: Washington DC
Posts: 2,042
My Ride: Audi S4midable
S4izzle is offline   Reply With Quote
Old 06-26-2006, 11:50 AM   #6
///OSS
Registered User
 
///OSS's Avatar
 
Join Date: Aug 2004
Location: MIA
Posts: 10,343
My Ride: "The.. 325CI"
Send a message via AIM to ///OSS Send a message via MSN to ///OSS
super sick I cant wait to see the final... looks like your living up to that PS buddy...lol

Im glad, its gonna be the sh it
///OSS is offline   Reply With Quote
Old 06-26-2006, 12:21 PM   #7
aznazasin
Registered User
 
Join Date: Oct 2005
Location: SoCal
Posts: 6,938
My Ride: Gets B!tches
Send a message via AIM to aznazasin
DAMN so basically you accomplished all that within 24 hours.....thats some insane custom work....cant wait to see the result
__________________
aznazasin is offline   Reply With Quote
Old 06-26-2006, 12:39 PM   #8
Two Outtakes
Registered User
 
Join Date: Nov 2005
Location: Newport Beach, Ca
Posts: 1,455
My Ride: is on 20" DPE's
great work! cant wait to see the final result
__________________


RETIRED EP Sedan
Two Outtakes is offline   Reply With Quote
Old 06-26-2006, 12:40 PM   #9
Choson1
Owner
 
Join Date: Dec 1969
Location: SoCal
Posts: 4,003
My Ride: Keepin' it Real
mad skillz man
__________________
Choson1 is offline   Reply With Quote
Old 06-26-2006, 12:55 PM   #10
jre.328i
Registered User
 
Join Date: May 2006
Location: Monterrey, MX.
Posts: 196
My Ride: 99 BMW 328i
ur crazy... i have never though in that, u might hae a lot of xtra time
jre.328i is offline   Reply With Quote
Old 06-26-2006, 01:00 PM   #11
iLLM3
Registered User
 
iLLM3's Avatar
 
Join Date: Jun 2004
Location: NYC
Posts: 10,307
My Ride: Boosted M3 + G35
Send a message via AIM to iLLM3
Quote:
Originally Posted by 3TARD


You are the king of custom fabrication on this board; excellent work
Agreed, i love seeing your threads, your so creative with custom work, that looks GOOD too! Question, is the original CSL hole open with mesh behind it? Why did you just leave it open with mesh on the otherside if so?

Martin
__________________


RUF R-GT2
07 E60 M5
01 996TT RWD/Stage 2+ turbo SOLD!!
03 G35 Nismo Daily
02 500+ HP SC M3 SOLD

www.e46psi.com
iLLM3 is offline   Reply With Quote
Old 06-26-2006, 01:01 PM   #12
LAFENGAS
www.thielstudios.com
 
LAFENGAS's Avatar
 
Join Date: Jan 2003
Location: West Palm Beach, FL
Posts: 1,333
My Ride: 330ci
Send a message via AIM to LAFENGAS
Quote:
Originally Posted by otherside
super sick I cant wait to see the final... looks like your living up to that PS buddy...lol

Im glad, its gonna be the sh it

I must say, Luis talked/PS'd me into wanting to do a modified CSL bumper. Props to Luis. Now if you happen to charm the ladies like you charm me....
LAFENGAS is offline   Reply With Quote
Old 06-26-2006, 01:04 PM   #13
iLLM3
Registered User
 
iLLM3's Avatar
 
Join Date: Jun 2004
Location: NYC
Posts: 10,307
My Ride: Boosted M3 + G35
Send a message via AIM to iLLM3
Quote:
Originally Posted by LAFENGAS
I must say, Luis talked/PS'd me into wanting to do a modified CSL bumper. Props to Luis. Now if you happen to charm the ladies like you charm me....
Lu is the man!
__________________


RUF R-GT2
07 E60 M5
01 996TT RWD/Stage 2+ turbo SOLD!!
03 G35 Nismo Daily
02 500+ HP SC M3 SOLD

www.e46psi.com
iLLM3 is offline   Reply With Quote
Old 06-26-2006, 01:05 PM   #14
BreakMyWallet
Registered User
 
Join Date: Oct 2005
Location: So Cal
Posts: 9,219
My Ride: B6 A4/ Mini Cooper S


DIY king
__________________
BreakMyWallet is offline   Reply With Quote
Old 06-26-2006, 01:08 PM   #15
m3racing
Registered User
 
Join Date: Nov 2004
Location: Cumberland MD
Posts: 4,203
My Ride: Yamaha R6
Send a message via AIM to m3racing
crazy skills. where did you buy the CF epoxy resin and the vacuum bag. I have Cf leying around but cant use it...
__________________
Cuong- PS3- AUKTANE6

m3racing is offline   Reply With Quote
Old 06-26-2006, 01:17 PM   #16
LAFENGAS
www.thielstudios.com
 
LAFENGAS's Avatar
 
Join Date: Jan 2003
Location: West Palm Beach, FL
Posts: 1,333
My Ride: 330ci
Send a message via AIM to LAFENGAS
Quote:
Originally Posted by m3racing
crazy skills. where did you buy the CF epoxy resin and the vacuum bag. I have Cf leying around but cant use it...

U.S. Composites
LAFENGAS is offline   Reply With Quote
Old 06-26-2006, 01:51 PM   #17
MCD007
Im The Man
 
Join Date: Dec 1969
Location: Sunnyvale, CA
Posts: 1,191
My Ride: 325ci
Send a message via AIM to MCD007
so when are you and mite46 gonna build a custom car again?
__________________
MCD007 is offline   Reply With Quote
Old 06-26-2006, 02:51 PM   #18
GunMoto
Registered User
 
Join Date: Dec 1969
Location: OC/SD, CA
Posts: 3,531
My Ride: EG8 | E46 | W211
Send a message via AIM to GunMoto
Impressive work!
__________________
GunMoto is offline   Reply With Quote
Old 06-26-2006, 03:13 PM   #19
iiimbpiii
Registered User
 
Join Date: Apr 2005
Location: Norcal
Posts: 1,375
My Ride: 07 SLK55, 08 R32
Send a message via AIM to iiimbpiii Send a message via Skype™ to iiimbpiii
That looks crazy... good luck with everything its going to to look!
__________________

07 SLK55: RENNtech CF airbox with Green Filters, Eurocharged/LET dyno tune, HEMs, CJs custom exhaust, Eisenmann quad P-car tips, Sprinbooster, H&R Springs, 19" Modular-Concept custom wheels, Euroteck CF front lip, Euroteck CF rear Spoiler, SL antenna, Clear reflectors, painted emblems... Soon to come: Looking into a TT setup!
iiimbpiii is offline   Reply With Quote
Old 06-26-2006, 03:16 PM   #20
fckupayme
Registered User
 
Join Date: Dec 2004
Location: Westchester, NY
Posts: 2,972
My Ride: Razor Scooter on 20s
DIY king does it again... very nice work. the hole looks very well planned and executed. cant wait to see it on ur car
__________________

fckupayme is offline   Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Censor is ON





All times are GMT -5. The time now is 12:30 PM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
(c) 1999 - 2011 performanceIX Inc - privacy policy - terms of use