1:1 Carbon Doors

[Epoustouflant]

To get on the waiting list, click here.
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Really excited about this new project.

I've been working on a complete an OEM 1:1 carbon door set made for the E46 M3. It will be a part of my Restoration & CSL'ification project.

The pending specs:

• Made with vacuum infused carbon fiber.
• Save about 60/70 lbs in total
• The carbon negative mold was made using an OEM door.
• 2x2 weave pattern
• 3x coats of 2 Component Hardened Clear Coat
• Weight: 2.4kg / 5 lbs per door
• Optional OEM metal crash bar
• Includes stainless mounting hardware

To get on the waiting list, click here.

My E92 doors:

[EthanolTurbo]

Looks really cool. Would love to see more details.

[Altaran]

Since they are making parts for German Brands, will they be able to provide a TÜV Material Test Report?
Asking because I live in Germany and I want to keep my car street legal even though its a track build.

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[Epoustouflant]

Since they are making parts for German Brands, will they be able to provide a TÜV Material Test Report?
Asking because I live in Germany and I want to keep my car street legal even though its a track build.

Gesendet von meinem Pixel 7 mit Tapatalk

I will ask, but doubtful this would pass TUV if I look at what Schirmer did.

[Epoustouflant]

Some progress on this!

I'm hoping to receive these within 4 weeks or so.




I've also documented the unboxing of my E92 door set here.

[Epoustouflant]

They're on their way.

[WestBankM4]

The pending specs were 5lbs per door, what's the final product weight since they're now in your possession?

[bigjae46]

Interesting. Looks like they used a kevlar/carbon weave on the backside layer. I’m working on a left door mold right now - the concern is carbon shatters and quickly breaks apart once elongated. The kevlar will at least hold the structure together.

The crash bar is aluminum. Couldn’t your manufacturer make one from kevlar like the OEM front crash bar? That would save a lot of weight and be much thinner.

The only other comment is the airbag mounting area, carbon or carbon/kevlar? Would it hold up if the airbag deployed? Or would it destroy the mounting area?

[Epoustouflant]

The pending specs were 5lbs per door, what's the final product weight since they're now in your possession?

The door itself is 3.7 kg, the bar adds 1.6 kg. Not yet in my possession!

Interesting. Looks like they used a kevlar/carbon weave on the backside layer. I’m working on a left door mold right now - the concern is carbon shatters and quickly breaks apart once elongated. The kevlar will at least hold the structure together.

Yes, that is the intention. Ultimately this is all theoretical as the budget to crash test this is not available. It's definitely a buyers beware.

The crash bar is aluminum. Couldn’t your manufacturer make one from kevlar like the OEM front crash bar? That would save a lot of weight and be much thinner.

They could - but we felt the OEM would be safer considering what you said above. Karbonius went with a carbon crash bar on their E92 doors.

The only other comment is the airbag mounting area, carbon or carbon/kevlar? Would it hold up if the airbag deployed? Or would it destroy the mounting area?

Great question, I will document this in detail once I get my hands on the door.

We can share notes when done! If it can help you in your project, I'd be glad.

[bigjae46]

We can share notes when done! If it can help you in your project, I'd be glad.

Absolutely. If you have any input on the final project, I would recommend integrating some kevlar into the layup and the inner skin. Kevlar is kind of the opposite of carbon. It still maintains most of its strength beyond its yield point so it will still hold its shape, thus not shatter.

The crash bar can also be kevlar.

Do be aware that Kevlar is difficult to work with - doesn’t cut easily and is a PIA to trim - hence the reason why it has its toughness properties. So there might be some added cost.

[Epoustouflant]

Absolutely. If you have any input on the final project, I would recommend integrating some kevlar into the layup and the inner skin. Kevlar is kind of the opposite of carbon. It still maintains most of its strength beyond its yield point so it will still hold its shape, thus not shatter.

The crash bar can also be kevlar.

Do be aware that Kevlar is difficult to work with - doesn’t cut easily and is a PIA to trim - hence the reason why it has its toughness properties. So there might be some added cost.

For sure, there is kevlar on the inner doors. I will ask how many layers were applied. You are entirely right on it - tensile strength is lower but it absorbs shock better.

It was put on the E92 doors as well. Those were clear coated - which wasn't smart at all. The E46 doors are arriving in raw carbon.

[bigjae46]

That should be good. I’d definitely explain that when you make the for sale post.

[jet_dogg]

Oct?

[Epoustouflant]

They are here: we already sanded them down and primer'ed them to resume the build.

[Epoustouflant]

We're moving! The door got sanded with block-sanding techniques to isolate uneven spots before primer. We did the first primer and more sanding to flatten it again - another primer session will be needed.