heinzboehmer's 2002 Topaz 6MT Coupe

[bigjae46]

Bryson sent me this: https://www.instagram.com/reel/DYAGESosIlI/

Looks like their strategy is similar?

Link not working

[heinzboehmer]

Link not working

Oh hmm, looks like they deleted the post?

Link still works on my phone, so maybe the app has it cached?

Whatever, here's a few screenshots:

[bavarian3]

So the cars I've pulled these from are junkyard e46 non-m with shit all over the place. I think without a seat and door would help free up space, but I'm going to tinker around with the loose headliner I have and see because now I'm curious.

Other areas I would think about (not necessarily an issue) is how it conforms along the ceiling and slides under the window moldings, and the panel in the back where the headliner curls over. As long as the fit is good i'm sure it's not a huge deal but these are areas I recall some flex aiding.

I'm guessing these reasons why a certain shop took 3 years to develop this, and unless they purchased up all the limited(and now not really available I have a backorder in) BM134 this would be a non-oe fabric.

[heinzboehmer]

So the cars I've pulled these from are junkyard e46 non-m with shit all over the place. I think without a seat and door would help free up space, but I'm going to tinker around with the loose headliner I have and see because now I'm curious.

Other areas I would think about (not necessarily an issue) is how it conforms along the ceiling and slides under the window moldings, and the panel in the back where the headliner curls over. As long as the fit is good i'm sure it's not a huge deal but these are areas I recall some flex aiding.

I'm guessing these reasons why a certain shop took 3 years to develop this, and unless they purchased up all the limited(and now not really available I have a backorder in) BM134 this would be a non-oe fabric.

Yep! The more I stare at this, the more it becomes obvious that there's no way a replica is gonna be better in any way than the BMW part. Weight, NVH, ease of install, etc.

BUT, being able to buy something beats not being to buy anything, so still seems like a worthy endeavor.

I can see how replicating these the traditional way (i.e. trashing a part(s) to pull a mold) drives development costs way up and makes the retail part end up priced like they've priced it. However, I think approaching it from the digital world would lower those costs significantly. Development cost basically becomes materials for the mold and a couple prototypes, then it's just a matter of cranking out parts.

[Obioban]

I think it'll go in even being completely rigid, I don't recall ever having to bend a coupe. The door frame is larger on a coupe than a sedan and they come out a sedan without bending as well. Worst case you take the door off, 3 bolts and a wiring connector, bingo bango.

I will admit, I did not think of taking off the door.

[George Hill]

Lol I guess I don't need to like this post since I like the IG post haha

...and the panel in the back where the headliner curls over.

I forgot about this aspect, I wonder how they are dealing with it? With a rigid panel I don't know if it structurally needs it and being in the back window its likely not seen but this is definitely the item that now sticks out to me.

[Bry5on]

Personally I’d trust a mold from an actual part over a scan and re-CAD first attempt. Glad they’re doing it, even if it doesn’t help my wagon situation. I’m still looking for a slicktop touring headliner :/

[heinzboehmer]

I forgot about this aspect, I wonder how they are dealing with it? With a rigid panel I don't know if it structurally needs it and being in the back window its likely not seen but this is definitely the item that now sticks out to me.

It doesn't curl up past 180 deg, so I think you would be able to wrap the carbon around the lip and just manage to demold the part. Tricky bit for sure though.

Personally I’d trust a mold from an actual part over a scan and re-CAD first attempt. Glad they’re doing it, even if it doesn’t help my wagon situation. I’m still looking for a slicktop touring headliner :/

Oh 100%, I do too. But I do think that having the model will make prototyping go much faster, since you don't have to track down another impossible to find part and take another mold.

I spent some time thinking about how to validate the model efficiently yesterday and I think that using SW to flatten the surface and then printing it out on one of those big paper plotters could work. Then offer up to the real part and see if there are any inconsistencies.

The surface flattening algorithm and assembly do introduce extra variables, but sounds better (and much faster) than trying to print/CNC a few full scale prototypes. Would still for sure need at least one full scale pink insulation CNC part to test fitment before trying to pull a mold though.