Boot luggage cover fallen apart

[Conrod]

It looks to me as though it should be possible to produce a 3D model of these for printing. If you're happy to send me your broken cover I could take detailed measurements and see what I can come up with. Obviously the two halves would need to be joined together using three countersink head bolts, but it may be possible (depending on the thickness of the top) to rebate the holes and conceal the bolt heads with flush plastic covers.

Is the other right cover a mirror image of the broken left one?

[PointedMarlin]

Conrod, I suspect if you could accurately 3D print an unbroken one then you wouldn’t need to bolt them.

As I explored how mine fitted together it seemed to be a two part process.

The top piece clips into the bottom piece at the back behind the bar (or the other way round I can’t remember) through essentially hooking itself together in a through, under & up motion whilst simultaneously the top piece secures to the bottom piece with three bits of plastic that clip into each other.

This secures the unit until it breaks.

[RobbiZ4]

Our 3D solution. Have a look at the following thread:

https://www-zroadster-com.translate.goo ... ax,nv,elem

Mine is successfuly in use since about 3 years.

The user "faulsocke" is the owner of the 3D file.

[mcbutler]

Try a dab of plastic adhesive on the inside of one of the parts, if it melts the plastic slightly, then glue it and clamp it for 24 hours, job done

[ronk]

I think it looks like a proper job with proper fasteners!

[Conrod]

Our 3D solution. Have a look at the following thread:

https://www-zroadster-com.translate.goo ... ax,nv,elem

Mine is successfuly in use since about 3 years.

The user "faulsocke" is the owner of the 3D file.

Many thanks for the link Robbi - I'll have a thorough read of that tomorrow!

[flybobbie]

I see the 3d version using carriage bolts

[Pondrew]

All the 3d printiing bollox aside. Three machine screws and nuts seem to do the trick!

I am more interested in why a broken plastic hinge on the shelf would stop the boot lid from closing (from the original post)? I am presuming the rear window panel and roof panel sit on the shelf when stowed and are controlled by hydraulic rams, with the microswitches making signalling the next stage.

Thinking about it logically, do the microswitches for the boot stowing have an "over stow" switch (best way I can explain what I mean)?

[RobbiZ4]

All the 3d printiing bollox aside. Three machine screws and nuts seem to do the trick!

Yes, the left one can be repaired with screws.

But the right one always breaks down in several parts due to a completely different issue compared to the left.

In addition, on many Z4 one or both broken parts are missing and require a complete replacemement => 3D printing is a valuable option.

Thinking about it logically, do the microswitches for the boot stowing have an "over stow" switch (best way I can explain what I mean)?

To be honest, this is the next Z4 rumor!

There is an additional hall sensor in the bottom of the boot, that checks the position of the luggage cover. If it's not closed, the roof will not start to move.

[flybobbie]

Problem with bracket is bad design and too little plastic to support the loads.
The bracket is designed to hold the cover in the correct position for it to lock in place and make the connection between metal plate on the left and hall switch. Otherwise it would be all floppy and a pain to line up.
The brackets break because if people are a bit too aggressive pulling out the protector it puts a point load on the little pins which are trying to hold the lid in the correct position. Then puts a splitting load on the plastic.
Something that looked good on a 3D cad system designed by a graduate, instead of being designed by a Victorian forge master.
https://www.youtube.com/watch?v=qLwqy7mabYQ

[RobbiZ4]

Problem with bracket is bad design and too little plastic to support the loads.

Correct, but at least, the 3 melted pins are too weak, not the brackets itself. This issue is based on these melted connections.

Interesting video, as it exactly shows the 2(!) different issues:

On the left, the 3 melted pins will break.

On the right, "somebody" at BMW decided to reduce the number of pins on the aluminum stick. That's the reason, why the load is as double as high on the remaining single pin and the bracket ALWAYS will break in a 45° angle. That's a typical sign for overloads, same as on house walls.

[flybobbie]

Yes bit odd the single pin.
Yes the melted pins a bit of a bodged idea.

[Big Bad Boris]

All the 3d printiing bollox aside. Three machine screws and nuts seem to do the trick!

I am more interested in why a broken plastic hinge on the shelf would stop the boot lid from closing (from the original post)? I am presuming the rear window panel and roof panel sit on the shelf when stowed and are controlled by hydraulic rams, with the microswitches making signalling the next stage.

Thinking about it logically, do the microswitches for the boot stowing have an "over stow" switch (best way I can explain what I mean)?

I have no idea about the operation of the sensors and switches, but just to confirm…. once I did my drilling and screwing fix the roof operated normally straight away. Generally as most on here have probably seen, if the boot cover is not fully in position the car just bongs at you and flashes up the yellow widow warning on the dash, until you get out and do the walk of shame round to the boot. I guess one of the switches/sensors does a last minute check before closing the boot cover and picked up the fact that although the cover was engaged, something wasn’t quite right, maybe at that point the dash should display a yellow warning showing bits of BMW busted plastic

[RobbiZ4]

I have no idea about the operation of the sensors and switches...
...I guess one of the switches/sensors does a last minute check before closing the boot cover ...

No, nonsense.

I've already posted an exact description in this thread. Why do you try to invent some new rumours?

It's a hall sensor, that checks the exact position of the cover. If one or both hinges fail, the required position can't be hit anymore.