Mercedes C AMG 63 - Focal Utopia MW 3,5 pillars mde by LBaudio

Started to work on Mercedes C AMG pillars that will house Focal MW 3.5 midrange drivers. Ill try to make pillars with a matching design to the previously made sails that were two part two tone finish - Paint/leather and house Focal TBE tweter.
https://i.imgur.com/tnAC2qp.jpg?1


so, lets start with the pics of the build:


rings cut on the laser
https://i.imgur.com/W1mA9L4.jpg
https://i.imgur.com/uSvayXb.jpg


a bit of additional ruther work on the rings - mids will be flush mounted, rings were chamfered on the back
https://i.imgur.com/MCBoTVh.jpg
https://i.imgur.com/7FngxfZ.jpg




https://i.imgur.com/RMBkiuz.jpg
Rings were soaked with polyester resin to obtain better bond between wooden ring and fiberflass filler

holes were drilled into the pillar and 3 layers of fiberglass applyed to them and trimmed


https://i.imgur.com/SNitThE.jpg
https://i.imgur.com/PrhQMsX.jpg


fiberglass was smoothed out and pillars were taped off with ALU tape
https://i.imgur.com/KktvH8X.jpg
https://i.imgur.com/PrCpBEG.jpg


demoulding wax applyed
https://i.imgur.com/5I6VQ7o.jpg


on the back side I made quick plaster mold that would prevent pillar warping


https://i.imgur.com/SRZF8yD.jpg

fiberglass was applyed to the pillars that will serve as a base for insert that will hold driver


https://i.imgur.com/wxT6dDY.jpg
https://i.imgur.com/4wLVOjS.jpg
https://i.imgur.com/TnownIC.jpg


pilot holes for aligment
https://i.imgur.com/ZTgnlpM.jpg
https://i.imgur.com/Zq5r77g.jpg


template for the insert shape
https://i.imgur.com/06WS0Np.jpg
https://i.imgur.com/aLX9jyW.jpg


inserts trimmed to desired shape
https://i.imgur.com/xnn7afZ.jpg


new fastenings holes for inserts were drilled
https://i.imgur.com/gujLnci.jpg


Pillar and insert merged and holes were made
https://i.imgur.com/JTR1WU6.jpg
https://i.imgur.com/7C4Z8Dr.jpg
https://i.imgur.com/iFgJB2t.jpg
https://i.imgur.com/mhUNfzj.jpg
https://i.imgur.com/7GJOTMA.jpg

Rings positioned after some 20 attempts, lol
https://i.imgur.com/P4CzRds.jpg
https://i.imgur.com/TQ2K0rw.jpg
https://i.imgur.com/SBc8UeH.jpg
https://i.imgur.com/EbWmpkF.jpg
treated inserts added to the insert
https://i.imgur.com/fxDm8kN.jpg
https://i.imgur.com/eTpXqLG.jpg

https://i.imgur.com/Z2BWnve.jpg
https://i.imgur.com/2nRcKNY.jpg
https://i.imgur.com/OUHOd8r.jpg

Started to build front fascia on insert - made quick template
https://i.imgur.com/xYMh08z.jpg
https://i.imgur.com/sdgjBHV.jpg
https://i.imgur.com/RGWpAFY.jpg
https://i.imgur.com/OPEYNws.jpg
https://i.imgur.com/GnEoa88.jpg
https://i.imgur.com/LbhlElY.jpg
https://i.imgur.com/Mc8dRbt.jpg


checking for clearance with speaker dummy
https://i.imgur.com/Htpl7Yt.jpg
https://i.imgur.com/188TaEU.jpg
https://i.imgur.com/ps2JJtP.jpg
https://i.imgur.com/gG76LvY.jpg

so here a re some additional pics


https://i.imgur.com/L7yZ9BX.jpg
https://i.imgur.com/IUpJuxY.jpg
https://i.imgur.com/mvHbQsX.jpg
https://i.imgur.com/bLCgDDZ.jpg


this is the end of part one with inserts ready for further fab

heres the pics of progress.... starting work on outer part - pillar itself:
Inserts were smoothed out to some degree


https://i.imgur.com/wnkfeKo.jpg
https://i.imgur.com/occo3KM.jpg
https://i.imgur.com/GLrtq2Q.jpg
https://i.imgur.com/u6a8aLh.jpg
https://i.imgur.com/ED18rV4.jpg


templates were made out of cardboard and taped off with ALU tape and attached to the insert


https://i.imgur.com/35gJ7nE.jpg
https://i.imgur.com/ZjpJ5PR.jpg
https://i.imgur.com/KkAwiVf.jpg


filler was applyed to the outer part of pillar and later also to the insert


https://i.imgur.com/RLQAyuL.jpg
https://i.imgur.com/zqK4IlK.jpg
https://i.imgur.com/UIE7xgZ.jpg

template and insert were removed, outer part roughly sanded down


https://i.imgur.com/hCaoDtN.jpg
https://i.imgur.com/u1KwprC.jpg
https://i.imgur.com/CSSzWh4.jpg
https://i.imgur.com/cUqRHbv.jpg
https://i.imgur.com/HrgVoJt.jpg

Now the fun part begin, sorting out all the gaps to be equal, everything smoothed down and ready for first hand of primer.
Base of pillar will getone additional mod - Focal logo "F" insert on top of the pillar
https://i.imgur.com/cc0VVws.jpg


a few pics of sanded pillars


https://i.imgur.com/eoiyGKK.jpg
https://i.imgur.com/ZBCwNUr.jpg
https://i.imgur.com/hlUzqKu.jpg
https://i.imgur.com/s4zs4Ji.jpg
https://i.imgur.com/Fbj8Dyj.jpg
https://i.imgur.com/nvtPIJV.jpg
https://i.imgur.com/Dna88tZ.jpg
https://i.imgur.com/DBR85cO.jpg
https://i.imgur.com/QpBCXeV.jpg
https://i.imgur.com/meg0aQs.jpg