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BMW 3-Series (E90 E92) Forum > BMW E90/E92/E93 3-series General Forums > Photo/Video/Media Gallery > E91 320d M-tech story -> DIY everything, but properly :)



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      10-31-2016, 12:42 PM   #23
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Wow love the E91, could use maybe just some H&R springs if your roads aren't good for coils
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      11-01-2016, 05:49 PM   #24
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Quote:
Originally Posted by mjn77 View Post
Forget that asthmatic diesel.......those roads!!!
Wow, i want to drive them now!!! I've never been any further east than Austria or south then Italy.
Next time, when you're headed this way, ping me and I'll tell you, where those roads are
Quote:
Originally Posted by McPikie View Post
Lovely looking wagon with some cool mods. That photo coming through the leaves too, oooooffft.

Any vids on how your exhaust sounds with the last muffler deleted? I'm considering it for my 320d
Tnx man
I was considering for a while to record one, since there were a few other guys, asking for such video. Here it is



Quote:
Originally Posted by Drifter2090 View Post
Wow love the E91, could use maybe just some H&R springs if your roads aren't good for coils
Tnx
I'll probably spend money on acoustics and brakes. Suspension will be upgraded after that
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      11-02-2016, 03:45 AM   #25
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Ooooooof. Love the sound of that. Sounds like it's got a sore throat.

Guess I will be getting booked in for a muffler delete soon
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      04-13-2017, 04:00 AM   #26
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OK, so I finally found some time to make a custom fiberglass subwoofer enclosure for my E91.
I've decided to go after sealed enclosure. And the most space to do it, was under the trunk. The enclosure has a volume of 23 liters. I'll use 10" driver for the job.

Before I've even got to the enclosure part, I had to make room for the soundwaves to be able to penetrate trough the shelf.

I wanted to keep it as stock as possible, but still strong enough to be able to throw the baby stroller into the trunk without worrying, that I'll break something.

So, the only option for me was to keep the original shelf and modify it:

I began with the pealing the fleece:


After seeing, what is inside (paper honeycomb) I've done the octagon and cut the 1,5mm perforated metal:


PITA task - removing the honeycomb to make perfect space for the perforated metal:


Fitting the Perforated metal:


After that, I've glued back the original carpet over the shelf and painted the metal. You'll see the pics later.


So, for the custom fiberglass trunk sub box:
There's no way that I would work in a car, so I've removed the "spare tyre" part from the trunk:


I've placed some bubble wrap as a base, so that I could remove the enclosure easier + to get that extra millimeter on each side, to be able to wrap the enclosure into fleece fabric.


Protecting the mold:



Fiberglass time:







I've used 2 layers of thinner mat and 2 layers of thicker cloth.
I also poured in 23 liters of water to make sure, that there arent any potential holes. Result - No leakage

Done. Removed it from the mold. Had to use the crowbar to pull it out


Cutting the enclosure to the correct height:


Checking if a cut was clean. Had to do a few little corrections after the initial cut:


Fitting the top of the enclosure and measuring, where to place the driver. You can also see the perforated metal on top:


Cutting the driver and terminal holes:


Test fit:


Another tweak: making a lid out of the MDF, so that it will fit perfectly:


I've also drilled some extra holes, so that the final layer of fiberglass will hug the MDF:


Squeezing the sealant to the lid:


After that I've placed the lid to the bottom part of the enclosure and once the sealant was dry, I've done another layer of fiberglass over the sealant area:



That's all for now.
Today, I'll glue the fleece fabric onto the enclosure and some leatherette on top of the enclosure. I'm expecting, that installation will happen on Saturday on Sunday.
Will post some pictures of the end product, once done

Can't wait

Last edited by inti; 04-26-2017 at 08:50 AM..
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      04-13-2017, 10:26 AM   #27
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This is something I really wanted to do with mine, but really cannot be fussed messing with fibreglass
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      04-13-2017, 04:24 PM   #28
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Quote:
Originally Posted by McPikie View Post
This is something I really wanted to do with mine, but really cannot be fussed messing with fibreglass
Do it. It's really simple. This was my first time and I loved it. I've found it really relaxing

OK, so I've ended this DIY project today.

I've started by cutting the fleece fabric to fit the box:


Job done:


Sealed the leatherette on lid:




Got some damping material for subwoofers. A piece for 20liter enclosure should do the trick.


Connected the cables to the terminal:


And this is the last time, when the interior saw a daylight:


Job done:


Driver used is ESX SX1040 (Signum series), 10", 400W RMS @ 4 Ohm.
I'll also replace the original speakers in the front doors and under the seat with ESX VS200C:

http://www.esxaudio.de/pages/vision/vs200c.htm

More to come.

Oh, do you think that this is maybe worth posting into the DIY section of the forum?

Last edited by inti; 04-13-2017 at 05:11 PM..
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      04-16-2017, 09:08 AM   #29
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Enclosure fits like a glove.


I ended up with ESX VS200C set and a 4 x 120W RMS amp.
The amp has a great feature: Bass remote control. I've installed the remote near the OBD port under the dashboard, so that it's accessible while driving, but still invisible to notice. Again: key factor was keep everything looking stock

All front 6 speakers were replaced and linked with the amp.
Hardware used:


And the final product. I'm very happy with the outcome



I also cut the original carpet, which was in the trunk, so that everything is now well hidden and neatly done:



Done
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      04-16-2017, 09:12 AM   #30
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Really nice install. I'd have been tempted to cut the box to make the sub enclosure wider, would require a backbox delete though.
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      05-21-2017, 12:11 PM   #31
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Just bought myself the latest laser cutter:







I'll put this into the CAD to cut the pieces from the metal.
Will take a few weeks I guess to finish this little project.
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      05-21-2017, 01:09 PM   #32
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Amazing photos and E91!
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      04-03-2018, 04:16 PM   #33
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I've been out for a while, but I was quite active lately.
I'm finalizing the idea, that kept me going for a few months now...

For now, just sending a teaser photo:



Final product shoud be installed in 1 month time. Till then, I need to work on the edges, gluing, wraping, painting....
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      04-04-2018, 10:28 AM   #34
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Wow! Awesome photos! Those 710s look perfect on that car... and that scenery! Great car and great post!
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      04-15-2018, 10:23 AM   #35
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Finally some progress...

I've glued the ABS plastic into a rear diffuser. I've sent the ABS plastic to have it cut using water jet. Then it was some gluing time.
After I've glued this together, I've painted it matte black.

Side part of the diffuser being glued:


Diffuser:


Before the installation:


In the background you can notice new front grill - F80 style.

I'll post some pics of the installed diffuser, once I'll use my DSLR camera.

To be continued....

Last edited by inti; 04-15-2018 at 10:48 AM..
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      04-17-2018, 10:28 AM   #36
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Omg, the encloser and overall install look amazing! Definitely put it in the diy section!

Love how the diffuser is coming too!
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      04-22-2018, 04:02 PM   #37
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Quote:
Originally Posted by Drifter2090 View Post
Omg, the encloser and overall install look amazing! Definitely put it in the diy section!

Love how the diffuser is coming too!
Tnx man


So, I decided to make some new stuff for my wagon.

Oh, I've dropped the wagon almost a year ago - it's was lowered with Bilstein B12 kit. Love it!

How it started:


Painted cardboard splitter beta release:


Side skirts:


I've used water jet cutter to cut the ABS plastic. I have a feeling, that I'll manage to break the splitter, skirts or rear diffuser soon, so I made 2 front splitters, 3 side skirts and 2 diffusers, just to have a backup piece in stock


I've roudned the edges, so that the 5D carbon fiber wrap would stick nicer:


Wraping in progress:


I also wraped new carbon fiber front splitters into transparent protective wrap:


After wraping, it was time to install the splitter and side skirts.
I've also made a holder in the middle:



This is one from today:


I'll make some more pics of rear diffuser...
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      07-28-2018, 02:28 AM   #38
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My buddy made some badass photos last week.





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      07-28-2018, 08:59 AM   #39
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Amazing photos! Even better e91. Looks perfect I wish we got diesels in the US.
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      07-28-2018, 11:30 AM   #40
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Very nice!!! love the scenery !!
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      08-03-2018, 04:01 AM   #41
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Some more shots from the airport photoshoot:









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      10-15-2018, 06:22 AM   #42
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I've just bought new tyres and rims for the winter setup. Until I'm waiting for the deadline, when I'll need to replace the setup, I've modified the wheel center caps a little

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      10-16-2018, 08:24 AM   #43
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Awesome work!
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      11-19-2018, 03:57 PM   #44
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Last minute job - just started snowing here and I had to push my buddy to install my fresh winter setup.
Will post more pics, when I'll wash it and take some better shots


Last edited by inti; 11-19-2018 at 04:05 PM..
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