[sirdaft1]

EDIT: I AM NO LONGER PURSUING MAKING THESE. I was going to make these simply because there was nowhere else to buy them. Fortunately over the past few months there have been a few other makers of this e90 sunroof insert enter the market. :-)

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It seems that no one is selling Carbon fiber/fiberglass sunroof inserts for the E90. This is an extremely popular modification on the E30/E36/E46 platforms for those who track their cars, as the sunroof and sunroof cassette are the heaviest and highest point for the center of gravity on the car. jlombar5 and I have been throwing around the idea of trying our hand at making some, if the interest is there.

Just curious, who would be interested? This is initially for the e90 guys as this is the model we have to test fit. But I'll include E92 in the polls as well (this is assuming they have different sunroofs?), but I would need a local E92 down the road if we pursue this avenue for test fitting purposes.

By removing then E90 glass sunroof and cassette which weighs an estimated 55-60lbs, and replacing with a sub 5lb CF insert, overall weight would be reduced from high CG area by roughly 50-55lbs.

This project would be more of a labor of love for this platform, as I avidly track my 335 and no one makes these for us

Pricing is TBD, but I would estimate in the $300ish + S&H range.

****EDIT**** Apparently there already exists a CF insert for the E92, just not us E90 guys. That said, development would likely only exist for E90's going forward.

This is a sample of what one looks like from an e36...

[sirdaft1]

I began working up a mold/plug for the e90. Coming along nicely.

[peterparker]

Why not just get the entire CF roof??

[sirdaft1]

Originally Posted by peterparker

Why not just get the entire CF roof??

Would love that, but @ $1500 + installation from IND, this should be a much simpler and cheaper alternative towards losing some high CG lbs.

[sirdaft1]

Quick update on progress: I spent a few hours on both Friday and Saturday creating the fiberglass mold. This stuff is a PITA and it gets everywhere!

Started with a sunroof from an e90 donor car...


3-4 layers of fiberglass later...


About to pull the sunroof from the fiberglass (absolutely essential to have a release agent on there!)


The completed mold...


Next it will need to be sanded, filled and sealed before taking it to the next step... Making CF panels via resin infusion!

[Ruddigger]

That's your mold? It doesnt look like you used tooling gelcoat, which is what should be used for moldmaking. That mold will work, but it wont hold up that well.

[jlombar5]

im excited

[sirdaft1]

Originally Posted by Ruddigger

That's your mold? It doesnt look like you used tooling gelcoat, which is what should be used for moldmaking. That mold will work, but it wont hold up that well.

Couldn't agree more. Without going into great detail it was either starting with this method which would be easier to create upfront and a possible pita on the back end (i.e.: a ton of pin hole bubbles to fill) or make a custom outer flange for the sunroof that fits, gel coat it then call it a day.

I'm no expert at fiberglass work, but very crafty and willing to learn. Due to the pinholes being a complete pain, I'm going to try method two with the gel coat sometime this week.

[Ruddigger]

I'm no expert either, but I have some experience fabricating and selling fiberglass parts. Fiberglasssite dot com is a great place for gelcoats and resins, shipping is a little high, but the resin quality is top notch.

[AK.]

Interesting. Subbed.

[matteblue3er]

Apparently these guys make it for the E90: http://dtmfiberwerkz.com/index.php?r...product_id=592

[sirdaft1]

Originally Posted by matteblue3er

Apparently these guys make it for the E90: http://dtmfiberwerkz.com/index.php?r...product_id=592

I forgot this thread was out there. I discontinued proceeding with these sunroofs as there are now a few different makers of the e90 sunroof insert (woot!).