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DIY: Do It Yourself
Post here to share or improve your wrench turning skills! All BMW E46 DIY tips, tales, and projects discussed inside. Learn to work on your car and know the right BMW parts you will need!

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Old 11-26-2013, 01:55 AM   #1
YYCZHP
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Custom CSL Trunk

Hey everyone, I'm really interested in a CSL trunk, however am worried about the fitment on the cheaper ones, yet don't want to spend excessive amounts of money on one such as a Vorsteiner one. So I thought about going about moulding my own off of an oem trunk. Obviously I would not do it on the one currently on my car as it would be more of an experimental thing and a learning experience. So here is what I was thinking and my two ideas I came up with:

Start with an oem trunk and sand down to the metal. From here I would apply a sense expanding foam in the general area. Obviously it's not going to look remotely close to a csl trunk. From here I would then sand it down into the general style of the csl trunk and apply fiberglass overtop of the foam. Sand it out and apply bondo, then sand it down to a smooth finish and paint.

My second idea was to skip the expanding foam idea in its entirety and just use either fiberglass or bondo.

By making my own, I believe I would eliminate the problems with fitment and it wouldn't be like any other csl trunk out there. If anyone has any thoughts or suggestions it would be greatly appreciated.



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Old 11-26-2013, 08:53 PM   #2
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You'd have to make sure the foam sticks to the trunk somehow, with all that vibration and jolting going on in a car's everyday life.

Perhaps drilling small holes for the foam to expand into.

You can make anything look good if you spend enough time on it. Good luck!
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Old 11-26-2013, 09:03 PM   #3
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Yeah I was thinking something along that line! Thanks for the advice!!


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Old 11-29-2013, 11:12 AM   #4
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I would think using foam and/or bondo will add unnecessary weight to your trunk and the trunk struts probably will no longer hold your trunk up, not to mention unwanted weight for performance.

If the existing aftermarket CSL trunks are not to your liking why not buy one and use bondo for fiberglass to make it the way you want? It is probably 99% to the way you want it as opposed to building from scratch - 0% the way you want it.
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Old 11-29-2013, 11:23 AM   #5
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Originally Posted by psykopsomatik View Post
I would think using foam and/or bondo will add unnecessary weight to your trunk and the trunk struts probably will no longer hold your trunk up, not to mention unwanted weight for performance.

If the existing aftermarket CSL trunks are not to your liking why not buy one and use bondo for fiberglass to make it the way you want? It is probably 99% to the way you want it as opposed to building from scratch - 0% the way you want it.
Well I think i was going to do a foam kinda mock up on the trunk, fiberglass over that so I have a fiberglass she'll, remove the foam and then fiberglass and bondo that to the trunk. Maybe a couple screws as we'll for safe measure and obviously bondo over them.

As for buying one and modifying it, first off you have to modify the keyhole, the light bracketry, adjust to fit the Taillights, and adjust the edge to get smooth lines. By no means am I a body man so I feel like although this sounds like an "easier" way to do it for a body man, for myself I feel as if this would result in more work. Not to mention I would still have to pay ~$500 for the trunk before paint and modification whereas I could go pickup a oem trunk for pennies on the dollar at pick n pull. Sweat equity my friend. Also it's a bit more personal satisfaction and a learning process.


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Old 11-29-2013, 11:36 AM   #6
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Well I think i was going to do a foam kinda mock up on the trunk, fiberglass over that so I have a fiberglass she'll, remove the foam and then fiberglass and bondo that to the trunk. Maybe a couple screws as we'll for safe measure and obviously bondo over them.

As for buying one and modifying it, first off you have to modify the keyhole, the light bracketry, adjust to fit the Taillights, and adjust the edge to get smooth lines. By no means am I a body man so I feel like although this sounds like an "easier" way to do it for a body man, for myself I feel as if this would result in more work. Not to mention I would still have to pay ~$500 for the trunk before paint and modification whereas I could go pickup a oem trunk for pennies on the dollar at pick n pull. Sweat equity my friend. Also it's a bit more personal satisfaction and a learning process.


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Modifying the keyhole and light openings is not that difficult. Considering you are willing to spend the time already to fabricate a CSL trunk I'm sure you can modify a CSL trunk working slowly to get it just right. Not being a body man I think you may find it much more challenging to get the lines just right fabricating from scratch. Another thing to consider that I forgot to mention earlier is the cracking of the bondo that will follow after opening and closing your trunk a few times.

Last edited by psykopsomatik; 11-30-2013 at 12:25 AM. Reason: correct spelling and grammar
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Old 11-30-2013, 10:42 PM   #7
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If you know anyone with a csl trunk all you need to do is see if you can make a mold of the lip portion of it by taping it all off and fiberglassing over the tape then boom theres your mold. Just add some mold release to the inside and fiberglass the inside of the mold. Then you have a damn near perfect section to add to your trunk besides the standard sanding and body fill.
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Old 12-01-2013, 02:04 AM   #8
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If you know anyone with a csl trunk all you need to do is see if you can make a mold of the lip portion of it by taping it all off and fiberglassing over the tape then boom theres your mold. Just add some mold release to the inside and fiberglass the inside of the mold. Then you have a damn near perfect section to add to your trunk besides the standard sanding and body fill.
Dude! Brilliant! Haha never thought of this!!!


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Old 12-01-2013, 10:14 AM   #9
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Hell you could do carbon fiber just as easily as fiberglass....
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Old 12-01-2013, 07:21 PM   #10
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Hell you could do carbon fiber just as easily as fiberglass....
Yeah definitely an option. I've looked at a bunch if diy carbon parts and seems like it's a real pita. Maybe down the road though!!


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Old 12-02-2013, 07:25 PM   #11
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Not really. All you need is a cardboard box, a small heater, and a vacuum bag. Just make sure you get pre impregnated carbon.
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Old 12-03-2013, 02:38 PM   #12
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Not really. All you need is a cardboard box, a small heater, and a vacuum bag. Just make sure you get pre impregnated carbon.
That's getting into some expensive territory though is it not? By the time you buy a trunk, the carbon, and the vacuum bag/pump you might as we'll have just picked up the Vorsteiner one though? Call me out on it if I'm missing something though haha


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Old 12-03-2013, 03:53 PM   #13
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Stumbled across this..why not skip the guesswork and hassle of trying to make it symetrical and just mold in one of these? This is just a generic link..I know I've seen these on ebay.

http://www.aliexpress.com/item/E46-c...506197084.html
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Old 12-03-2013, 04:10 PM   #14
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Stumbled across this..why not skip the guesswork and hassle of trying to make it symetrical and just mold in one of these? This is just a generic link..I know I've seen these on ebay.

http://www.aliexpress.com/item/E46-c...506197084.html
Yeah actually stumbled across that this morning and was thinking about it!


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Old 12-04-2013, 08:02 PM   #15
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That's getting into some expensive territory though is it not? By the time you buy a trunk, the carbon, and the vacuum bag/pump you might as we'll have just picked up the Vorsteiner one though? Call me out on it if I'm missing something though haha


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This would be in the scenario that you knew someone with a csl trunk already and you made a mold from their trunk. Pre impregnated carbon is fairly cheap depending on where and how much you buy. You can use just about any vacuum bag you want. Just have to make sure it is big enough. Not sure if you think that I was saying to do the whole trunk in carbon or not but I was talking about just doing the lip section in carbon.
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Old 12-04-2013, 08:05 PM   #16
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Yeah actually stumbled across that this morning and was thinking about it!


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The one problem I see with this is the sides. They don't roll into the rest of the body like a real csl boot lid would.
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Old 12-05-2013, 10:13 PM   #17
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The one problem I see with this is the sides. They don't roll into the rest of the body like a real csl boot lid would.
Yeah... May end up just going with a full cf csl trunk and leaving it exposed as my car is already sapphire black. This project seems to be getting more and more expensive as it progresses. There's a local oem trunk for sale for $280, plus parts and random supplies call it $50, then paint is going to be around $300. I'm already up to $630 haha.


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Old 12-06-2013, 09:36 PM   #18
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Who's charging you 300 to paint a trunk? I had front/rear bumpers, hood and side skirts on my e36 painted hellrot (red is a very expensive paint compared to anything else) for 300. Maybe do a little bit of shopping for paint or spray it yourself! Always a good skill to have.
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Old 12-06-2013, 09:46 PM   #19
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This is a terrible idea.



Sorry OP, not trying to come off as a D!ck, but someone had to tell ya

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Old 12-07-2013, 01:23 AM   #20
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Lol... I wanna see progress pics..
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