E90 Track Build - Custom Roll Bar/Brake Ducts/Sunroof Delete/Mode Carbon GTS Lip

FrenchBoy · 05-22-2015, 11:33 AM

Subscribed. This could be my future... Thanks for sharing

evilspiritM3 · 05-27-2015, 07:25 PM

Into the paint booth-

evilspiritM3 · 05-29-2015, 07:42 AM

So without any experience I embarked on the task of making a carbon sunroof panel. Made a few mistakes, and would do things a little differently next time, but on the whole this is a very doable task, and in total cost me about $115 in materials.

I wont say it is the prettiest piece, but should fit nicely in the roof and considering no vendor makes this, was the best, lightest alternative.

Fiberglass mold with edges to screw into existing holes in sedan roof:

Carbon fiber sheets in mold:

Completed piece getting some clearcoat:

Installed- still needs some finishing work. But the fit and strength is good.

evilspiritM3 · 05-30-2015, 07:45 AM

So work is completed on the roll bar, seat, and the carbon sunroof panel installed pretty cleanly.

At VIR this weekend shaking out the changes

Starting weight: 3609

After weight loss: 3177

Final weight: 3317

tlp · 05-30-2015, 12:56 PM

Looks good. You can probably shed another 75-90lbs with a titanium exhaust & lwt battery.

evilspiritM3 · 05-31-2015, 06:47 PM

Quote:

Originally Posted by tlp

Looks good. You can probably shed another 75-90lbs with a titanium exhaust & lwt battery.

I saw your VP battery install. Looks like the best way to go. Thanks.

DB · 06-01-2015, 03:23 PM

Looks like BPC did a really good job with that bar! All looks good...thanks for sharing.

M3 Number 86 · 06-03-2015, 07:04 PM

cf doors next!!

evilspiritM3 · 06-04-2015, 01:09 AM

Quote:

Originally Posted by socal TW

cf doors next!!

If only they existed for a sedan. . . .

Brake cooling is next. Tearing through rotors too quickly-

tlp · 06-13-2015, 03:13 PM

Quote:

Originally Posted by evilspiritM3

I saw your VP battery install. Looks like the best way to go. Thanks.

Nice. Looking forward to the final weigh in

w0ady · 06-13-2015, 03:49 PM

Quote:

Originally Posted by evilspiritM3

If only they existed for a sedan. . . .

Brake cooling is next. Tearing through rotors too quickly-

Maybe try a different pad compound?

evilspiritM3 · 06-13-2015, 06:21 PM

Quote:

Originally Posted by w0ady

Quote:

Originally Posted by evilspiritM3

If only they existed for a sedan. . . .

Brake cooling is next. Tearing through rotors too quickly-

Maybe try a different pad compound?

Yeah, switched from PFC 01s to PFC 11s so I will see if they are any improvements in terms of wear.

w0ady · 06-13-2015, 07:31 PM

Cool, I'd still do ducting cause it will only help.

soursamo · 06-14-2015, 01:00 AM

I'd buy an insert if you're going to make more!
Re use that mold!

evilspiritM3 · 06-14-2015, 05:34 AM

Quote:

Originally Posted by soursamo

I'd buy an insert if you're going to make more!
Re use that mold!

So, the mold didn't survive the carbon piece being removed. I was amazed by how strong and resilient the carbon is. Went a few physical rounds wrestling the carbon from the mold. Didn't use enough mold release wax in a few spots.

That being said, now that I have gone through this process, I would not make another mold. I would just lay the carbon over the glass panel (similar to how I made the mold) with the right overhang, and that would actually create a better fit all around.

I am now in the process of moving, so arts and crafts projects are not on the schedule right now. Once I get out to CA I may pump out 2-3 more. I learned a ton about working with these materials and subsequent editions would be much nicer. I may make a better version for myself too.

Materials are not expensive- check out soller composites.

mkPOTO · 06-14-2015, 11:52 AM

Very cool build!

evilspiritM3 · 06-14-2015, 04:55 PM

At VIR two weeks ago. Car is at BPC for brake ducting and lwt battery install.

M3 Number 86 · 06-22-2015, 11:57 PM

Quote:

Originally Posted by evilspiritM3

So, the mold didn't survive the carbon piece being removed. I was amazed by how strong and resilient the carbon is. Went a few physical rounds wrestling the carbon from the mold. Didn't use enough mold release wax in a few spots.

That being said, now that I have gone through this process, I would not make another mold. I would just lay the carbon over the glass panel (similar to how I made the mold) with the right overhang, and that would actually create a better fit all around.

I am now in the process of moving, so arts and crafts projects are not on the schedule right now. Once I get out to CA I may pump out 2-3 more. I learned a ton about working with these materials and subsequent editions would be much nicer. I may make a better version for myself too.

Materials are not expensive- check out soller composites.

california? I need one. this dumbbell on the roof is getting old at the track!!

Acree · 06-23-2015, 12:36 AM

Not sure who you're using to host the images, but they are awful at loading. 70% don't even show up.

But awesome build!

jeff@autocouture · 06-25-2015, 01:56 PM

car looks great, love the progress and diy

evilspiritM3 · 06-26-2015, 12:23 PM

Brake ducting complete. BPC put together a unique set up with the ducting intake. The backing plate has just about perfect fitment inside of the rotor and hat.

roastbeef · 06-28-2015, 10:06 PM

ducting is interesting. i haven't seen one yet that tucks inside of the rotor like that. any rubbing?

05-22-2015, 11:33 AM	#23
FrenchBoy Lieutenant Colonel 234 Rep 1,508 Posts Drives: '16 F80 M3 Join Date: Mar 2006 Location: Seattle, WA iTrader: (0)	Subscribed. This could be my future... Thanks for sharing __________________ Current: 2016 F80 M3 6-Speed \| SO \| AB XT1 \| ZCP \| M Performance Suspension \| GC Camber Plates Previous: 2009 E90 M3
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05-27-2015, 07:25 PM	#24
evilspiritM3 Captain 409 Rep 632 Posts Drives: 2011 E90 M3, 2018 F87 M2 Join Date: Nov 2006 Location: Virginia Beach, VA iTrader: (6) Garage List 2018 F87 M2 [0.00] 2011 M3 [0.00]	Into the paint booth- __________________
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05-29-2015, 07:42 AM	#25
evilspiritM3 Captain 409 Rep 632 Posts Drives: 2011 E90 M3, 2018 F87 M2 Join Date: Nov 2006 Location: Virginia Beach, VA iTrader: (6) Garage List 2018 F87 M2 [0.00] 2011 M3 [0.00]	Carbon Sunroof Inser Fabrication So without any experience I embarked on the task of making a carbon sunroof panel. Made a few mistakes, and would do things a little differently next time, but on the whole this is a very doable task, and in total cost me about $115 in materials. I wont say it is the prettiest piece, but should fit nicely in the roof and considering no vendor makes this, was the best, lightest alternative. Fiberglass mold with edges to screw into existing holes in sedan roof: Carbon fiber sheets in mold: Completed piece getting some clearcoat: Installed- still needs some finishing work. But the fit and strength is good. __________________ Last edited by evilspiritM3; 05-31-2015 at 06:54 PM..
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05-30-2015, 07:45 AM	#26
evilspiritM3 Captain 409 Rep 632 Posts Drives: 2011 E90 M3, 2018 F87 M2 Join Date: Nov 2006 Location: Virginia Beach, VA iTrader: (6) Garage List 2018 F87 M2 [0.00] 2011 M3 [0.00]	So work is completed on the roll bar, seat, and the carbon sunroof panel installed pretty cleanly. At VIR this weekend shaking out the changes Starting weight: 3609 After weight loss: 3177 Final weight: 3317 __________________
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05-30-2015, 12:56 PM	#27
tlp Colonel 276 Rep 2,216 Posts Drives: 991 GT3, Sold:'11 e92 M3 SG/FR Join Date: Jul 2005 Location: Las Vegas/SoCal iTrader: (6) Garage List SOLD 2011 BMW e92 M3 [9.10]	Looks good. You can probably shed another 75-90lbs with a titanium exhaust & lwt battery. __________________ 991 GT3, Sold: '11 e92 M3 SG/FR ZCP\|ZCV\|ZP2\|2MK\|494\|415\|6NR\|752
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06-01-2015, 03:23 PM	#29
DB M3/Raptor 48 Rep 302 Posts Drives: to the track Join Date: Mar 2010 Location: near Philly iTrader: (2)	Looks like BPC did a really good job with that bar! All looks good...thanks for sharing. __________________
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06-03-2015, 07:04 PM	#30
M3 Number 86 Major General 3221 Rep 6,218 Posts Drives: black m3 Join Date: Mar 2015 Location: pasadena iTrader: (1)	cf doors next!!
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06-13-2015, 07:31 PM	#35
w0ady Lieutenant 78 Rep 456 Posts Drives: 2008 E92 M3 Join Date: Apr 2015 Location: Jacksonville, FL iTrader: (0) Garage List 2008 BMW M3 [0.00]	Cool, I'd still do ducting cause it will only help. __________________ 2008 Sparkling Graphite E92 M3 DCT SOLD www.flatoutmotorsports.us (We host track events in the Southeast)
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06-14-2015, 01:00 AM	#36
soursamo Captain 163 Rep 799 Posts Drives: 2008 E92 M3 Join Date: Dec 2010 Location: BC Canada iTrader: (13)	I'd buy an insert if you're going to make more! Re use that mold!
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06-14-2015, 11:52 AM	#38
mkPOTO Mr. Nice Says Hello 636 Rep 16,662 Posts Drives: BMW M3 \| X5 xdrive 35i MSport Join Date: Dec 2008 Location: USA iTrader: (25) Garage List 2002 Lexus GS300 [0.00] 2008 BMW E92 M3 [5.58]	Very cool build!
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06-14-2015, 04:55 PM	#39
evilspiritM3 Captain 409 Rep 632 Posts Drives: 2011 E90 M3, 2018 F87 M2 Join Date: Nov 2006 Location: Virginia Beach, VA iTrader: (6) Garage List 2018 F87 M2 [0.00] 2011 M3 [0.00]	At VIR two weeks ago. Car is at BPC for brake ducting and lwt battery install. __________________ Last edited by evilspiritM3; 06-14-2015 at 05:08 PM..
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06-23-2015, 12:36 AM	#41
Acree Captain 378 Rep 850 Posts Drives: Waiting... Join Date: May 2014 Location: Dallas, TX iTrader: (2)	Not sure who you're using to host the images, but they are awful at loading. 70% don't even show up. But awesome build!
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06-25-2015, 01:56 PM	#42
jeff@autocouture BimmerPost Supporting Vendor 966 Rep 13,780 Posts Drives: 2002 E53 X5 4.6is Join Date: Jan 2010 Location: New Jersey iTrader: (0)	car looks great, love the progress and diy
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06-26-2015, 12:23 PM	#43
evilspiritM3 Captain 409 Rep 632 Posts Drives: 2011 E90 M3, 2018 F87 M2 Join Date: Nov 2006 Location: Virginia Beach, VA iTrader: (6) Garage List 2018 F87 M2 [0.00] 2011 M3 [0.00]	Brake ducting complete. BPC put together a unique set up with the ducting intake. The backing plate has just about perfect fitment inside of the rotor and hat. __________________
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06-28-2015, 10:06 PM	#44
roastbeef Lieutenant General 11585 Rep 12,725 Posts Drives: E92 M3 Join Date: Nov 2010 Location: Orange County, CA iTrader: (4)	ducting is interesting. i haven't seen one yet that tucks inside of the rotor like that. any rubbing? __________________ Instagram; @roastbeefmike
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