Mercedes Benz C 63 AMG sail panels for Focal Utopia M tweeter by LBaudio

L

LBaudio

Noob
[FONT=&quot]Started to work on Sails for Merc C AMG... Those will be two part sails where one part will be wrapped in leather, and the center piece - insert will be painted in cars paint. Here are pics of fabrication. Ill post finished pics after the customer receive them.[/FONT]
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[FONT=&quot]so started with original part - I applyed a layer of fiberglass over the entire sail panel after it was sanded down and drilled a bounch of holes[/FONT]
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[FONT=&quot]trimmed and sanded down[/FONT]
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[FONT=&quot]Made a duplicate of sail fascia out of fiberglass that will serve as base for insert[/FONT]
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[FONT=&quot]trimmed[/FONT]
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[FONT=&quot]next step was positioning of tweeter cups (Thanks to Peter Steinbacher/PSsound for providing them), paint was removed from cups, everything was taped off with ALU tape. Tweeter cups were glued to the base with hot mixed filler[/FONT]
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[FONT=&quot]transition from tweeter cup to base was smoothed out, started to work on shape design[/FONT]
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[FONT=&quot]next step was to smooth transition to the original sail panel with gap between the two pieces.[/FONT]
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[FONT=&quot]guiding coat applyed[/FONT]
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[FONT=&quot]primer applyed and sanded down up to 2000 grit water sandpaper[/FONT]
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[FONT=&quot]in meanwhile outer part of sails was wrapped in leather[/FONT]
 
[FONT=&quot]test fit[/FONT]
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[FONT=&quot]everything fits like a glow,... center pieces are getting second layer of primer and then they will be ready for paint.[/FONT]
 
[FONT=&quot]heres pictures of painted inserts and assembled.[/FONT]
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Fantastic. I've looked at this 12 times and still can't believe what i'm seeing. Inspirational to say the least. I may have to try this technique in the future. The real trick is joining the two parts together. Did you shape he outer shell and simply trace around it onto the original factory sail and then cut along the trace line?
 
Stycker said:
Fantastic. I've looked at this 12 times and still can't believe what i'm seeing. Inspirational to say the least. I may have to try this technique in the future. The real trick is joining the two parts together. Did you shape he outer shell and simply trace around it onto the original factory sail and then cut along the trace line?
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First thing i did was to smooth original sail panel. Then i did mold of original sail panel. I made three pilot holes trough both pieces that ensured that piece of mold/ insert base stay always in same spot. Then i trimmed that mold to desired shape and that part was a base from where i set tweeter cups and built basic shape of the insert. So this piece is removable from original sail panel from the beginning. Then i traced inserts perimeter with dense cardboard of appropriate thickness to account for vinyl thickness. I put insert in place and aded filler from both sides, on outer side i just blended shape to outer sail perimeter. Then i removed cardboard and got that gap between the two pieces. Then i sanded down sail panel with attached insert to get smooth transition between the pieces.
Insert piece remained removable. Pieces were glued together with hot glue at the end, so they can be separated if needed in hot watter - at approx 65-70 degrees without demaging any finish.
hope that clears things for you.
 
Thank you for the explaination. I am going to toy with this in the future. I'm sure it takes a lot of time and patience. Practice and screwup over and over again. Thanks for sharing.
 
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