You may already know I have created a post about making my Z4 roadster lighter & making my own carbon fibre parts.
I mentioned that I might make copies of my Side Covers in CF. This seems to have shown a lot interest, we all know how hard it is to get your hands on a good set.
I have decided to create a separate post specifically dealing with my attempt at replicating the covers as close as possible to the genuine item.
I was lucky enough to a buy a set from another forum member earlier this year. I love the way they finish off the look of the car & I totally understand why they are so popular.
Last night I started looking that the covers in a lot more detail, studying their design & construction materials.
The cover, (minus the vinyl layer) is 3mm thick & made from ABS ( Acrylonitrile butadiene styrene). It’s widely used in the production of injection moulded parts.
The advantages are, impact resistance, toughness & a certain amount of flexibility.
The flexibility aspect caught my eye because when I fit them to my Z4 I sometime have to slightly flex them to get them in place correctly. I don’t know if that’s just me fitting them wrong?
There is a domed piece that is the interface between the two parts of the locking lug. This is made separately from a hard plastic then bonded to the cover.
The locking lug is made up of two parts, again these are a hard plastic, but not as hard as the dome interface. I believe they are designed to come apart to avoid damaging the covers if you forget to remove them before closing the soft top.
Lastly the fabric layer on the cover looks the same as what on the dashboard. I’m assuming it’s a printed vinyl effect & looks like its glued on.
My plan is to try two different materials to make the main cover body. The first will involve using 3mm thick ABS sheet. I will have to make a vacuum former table & a heating station. This will allow me to vacuum form copies from a plug.
The second option is to make Fibreglass copies from a mould. It is the easier option, but it depends on how the parts performs when finished.
The dome interface & lug components will be cast in either Polyurethane or Epoxy resin.
The vinyl fabric can be sourced from a number of different web-based companies.
If I can produce copies that are to a high standard & close to the original cover then I will make sets for members on request.
Obviously at this moment in time I don’t have an idea how much it will cost to produce them & what they will sell for.
If anyone is interested in buying copies, or have any views regarding this please feel to post your thoughts.
Here is a few photos of the individual components.
I mentioned that I might make copies of my Side Covers in CF. This seems to have shown a lot interest, we all know how hard it is to get your hands on a good set.
I have decided to create a separate post specifically dealing with my attempt at replicating the covers as close as possible to the genuine item.
I was lucky enough to a buy a set from another forum member earlier this year. I love the way they finish off the look of the car & I totally understand why they are so popular.
Last night I started looking that the covers in a lot more detail, studying their design & construction materials.
The cover, (minus the vinyl layer) is 3mm thick & made from ABS ( Acrylonitrile butadiene styrene). It’s widely used in the production of injection moulded parts.
The advantages are, impact resistance, toughness & a certain amount of flexibility.
The flexibility aspect caught my eye because when I fit them to my Z4 I sometime have to slightly flex them to get them in place correctly. I don’t know if that’s just me fitting them wrong?
There is a domed piece that is the interface between the two parts of the locking lug. This is made separately from a hard plastic then bonded to the cover.
The locking lug is made up of two parts, again these are a hard plastic, but not as hard as the dome interface. I believe they are designed to come apart to avoid damaging the covers if you forget to remove them before closing the soft top.
Lastly the fabric layer on the cover looks the same as what on the dashboard. I’m assuming it’s a printed vinyl effect & looks like its glued on.
My plan is to try two different materials to make the main cover body. The first will involve using 3mm thick ABS sheet. I will have to make a vacuum former table & a heating station. This will allow me to vacuum form copies from a plug.
The second option is to make Fibreglass copies from a mould. It is the easier option, but it depends on how the parts performs when finished.
The dome interface & lug components will be cast in either Polyurethane or Epoxy resin.
The vinyl fabric can be sourced from a number of different web-based companies.
If I can produce copies that are to a high standard & close to the original cover then I will make sets for members on request.
Obviously at this moment in time I don’t have an idea how much it will cost to produce them & what they will sell for.
If anyone is interested in buying copies, or have any views regarding this please feel to post your thoughts.
Here is a few photos of the individual components.
I don’t want to under value the genuine item. :roll: 
