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First of the new models we’re working on: 2011 BMW 535i

In an effort to start offering products to new makes and models, we recently put a call out to see if we could find some high end car owners willing to send us their interior trim so we could work our magic.  The first person we found was a 2011 535i owner, and he got us his trim pretty quick.  We’re about halfway through his set, so we figured we’d share the progress.

The OEM trim is an aluminum stamped trim that looks okay.  You’ll notice its got a nice chrome accent edge, which we’ll retain.  It also has some nice contours on the pieces which we will try to keep as much as we can (the thickness of the fabric will dilute them a bit, but they still should be noticeable).

First step is to remove the chrome edges and peel back the aluminum.  After that is completed, we grind down to plastic to make room for the carbon and to give the epoxy something to adhere too.

Then we cut the fabric down to size and get it ready for wrapping.  We went with an 11oz 2×2 twill on this set.  I wanted to do a 20oz 2×2 twill, but I was afraid of it being too thick and there being fit issues with the chrome accent on some of the pieces.

And now the fun begins and the set starts to take shape.

The door pieces are a lot thinner without the chrome accents.  You can see the contours have been retained.

The dash piece is massive.

Love this shifter piece.  I can’t wait to see how it looks finished.

That’s it for now.  We’ll get epoxy on these over the next few days and do another update then.

To get an idea of how this will look finished, check our gallery, in particular the gallery of an e90 BMW:

http://ocarbon.com/gallery/bmw/patrick

e60 BMW carbon fiber trim set is almost done…

just needs a quick wetsand and polish and it will be ready to get shipped out to the customer.   We used an upgraded 20oz 2×2 twill fabric on it, with the weave going in all one direction.  Very happy with how it turned out.

just got started with our first e60 m5 set of trim…

We’ve done a few BMW sets in the past, mostly e46 and e90 sets, but now we’re about halfway done with our first M5 set.  I’m really happy with how it is turning out so far, particularly the shifter piece.  I can’t wait to finish this set up and see how it looks installed.

We start with an e60 wood core that gets sanded down to make room for the extra material of the carbon fiber and epoxy.

After laying the pieces out on the fabric (we went with an upgraded 20oz 2×2 twill for the M5), we carefully cut it out to the appropriate sizes.

We then mix up some bonding epoxy and apply it to the pieces.

A few hours later, the fabric has been applied and the first major step on the trim is completed.  This week, we’ll start adding epoxy to the pieces to give it the gloss and depth that most people associate with carbon fiber.

 

Finished up the e90 BMW carbon fiber trim…

and it will be shipping out shortly.  We just need to give it a few days to cure before it gets a final polish and gets shipped out.

I’ll make sure to post a bunch of pictures after everything is installed.

e90 BMW carbon fiber trim production…

We just started our first official set of BMW carbon fiber trim.  It’s for a 2006 e90 325i sedan.  We decided to wrap it in an upgraded 20oz 2×2 twill fabric to make sure the trim really stood out.  Once this is done we’ll start an e92 set (hopefully from an M3) and it will get the same treatment.  Stay tuned for more details and pricing…

 

First we took the stock wood set, sanded it down to make room for the carbon fiber, and added a coat of bonding epoxy.

Once the epoxy had firmed up a bit, we began to wrap the pieces in the 20oz 2×2 twill fabric.

Next comes the long process of slowly building up the epoxy on the surface to give the pieces depth.

That’s all for now.  I’ll post more pictures after the epoxy has cured and the pieces have been trimmed, sanded, and cleaned up for clearcoat.

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