Z4 Coupe Full moonroof tops -In process

[Twisted Six]

Since I'm in current tooling construction for Resin Infusion molds for the Z4C's for making a 'BEST' version of Carbon Fiber-(CF) roofs....I decided to double up and ALSO build a high heat mold tool to be used professionally via a Polycarbonate/Acrylic manufacturer.

I have also started the process for a fully adapted inner headliner to be used for >

1)-A Removable OEM metal roof kit.
2)- A removable CF roof kit.
3)-A removable clear/tinted-UV protected OEM appearance roof kit.

Both the kits #2 & #3 will also be able to be mounted permanently as well if so chosen.

Prototype pictures mounted and unmounted will be shown here as soon as its mold tool and one unit is completed -(Pre-production run).

I'd like our true RACE drivers to investigate their component rule books in regards to Polycarbonate in place of glass for track use please.

The glass manufacturer has mentioned great benefits in regards to using a Impact modified UV stable ACRYLIC rather than simply Poly.

Those differences are >>

1)-Poly , although 250 times stronger than glass , can shard under final failure status....becoming dangerous of course. But still able to withstand hits better than a steel roof shear. (open to opinion).

2)-Acrylic (impact modified )...does not shard ,rather under final fail...it shatters into tiny bits, not unlike tempered glass that's OEM in your side glass.

1)-Poly-(with UV coatings)- If the coating becomes scratched through....it cannot be sanded and polished away...nor easily/afford-ably re-coated.

2)-Acrylic -(UV molded)- Has a clearer optic level as well as being able to sand/polish when scuffed/scratched..due to having the UV inhibitor infused in its semi-liquid construction.

1)-Both can be ordered tinted at different levels...however Acrylic is the only one which can also be secondarily tinted from the inside with sheet tints such Llumar and 3M type films to better match your heat resistant and appearance !

In regards to the inner headliner....I believe you'll all like the trim points and how it will look OEM in design and function.

For the kits being ordered with removable roofs....the fastener methods will be intuitive and not time consuming to operate.

Although the OEM roof WILL fit inside the closed hatch of the coupes....this is NOT a safe travel option and therefore should be forbidden and I will not engineer any form of internal holster to hold the roof when stored. Forget it.

Rather...I have engineered a No-external fastener visible Stay-fast canvas temp top for days when a shower comes out of nowhere or your going inside to eat for an hour etc.

This thread is simply an introduction of the project and to share positive thoughts or safety concerns or even just comments towards the goals end.

Once the molds and prototype is installed and kinks worked out with test drives and exposure along with destructive tests....and photographed....I will open things up for orders within regards to all forms of kits.

Thoughts ??

Here is a link to a Mercedes all glass ELECTROMATIC roof....for simply a visual reference. My roofs WILL NOT be ELECTROMATIC...nor would you wish to pay for this in the end....you know it.

(http://www.worldcarfans.com/11010082...ochromic-glass)

Cheers, Vinny

[jdl1pt]

I think this is one of the best ideas I've heard of in a long time. Love the idea of a see through top, and the ability to run without one. I'm subscribed.

[Shereef_Osman]

This should be awesome! Great job man.

[azadian2b]

I love you.

[robrwalker]

Originally Posted by azadian2b

I love you.

I love him more. ;-)

[MIKe86]

suscribed!


edit: I know it's still early, but if you has to estimate a pricepoint what would you say...?

[BlackMoupe]

This is amazing. I wish you the best of luck In developing this, and I look forward to purchasing one

[z4mnyc]

Subscribed!

[Rick Hunter]

Oh so subscribed!!!

[CobraR1339]

Bring It !

[cmark8]

why are such magnificent ideas and projects coming up when I'm about to part my car out???

[Twisted Six]

Originally Posted by MIKe86

suscribed!


edit: I know it's still early, but if you has to estimate a price-point what would you say...?

Thanks for the positive energy's everyone.This is going to be involved and costly on the front-side development .

It requires three molds >For the top alone.

1)-Substructure -(as did the OEM)
2)-Top skin.
3)-fastening point reinforcements.

Then it requires two molds for the inner headliner >( As well as liner cloth)

1)-Modified inner -(part that you'll see)
2)-Substructure-(for factory mounting clips)

And then requires molded Urethane or rubber bump-stops....as well as fastener points.

I also have to source a pinch/flexible rubber seal that can attach to an inner aluminum or stainless lip which will replace the OEM removed Urethane sealant/adhesive.

And of course some nice Stainless components for fastening the roof either permanently or temporarily.

As in ALL projects aiming towards production.....price points are being layed out as we speak. Final cost of a kit whether it be CF or OEM or Acrylic/Poly will soon enough be determined.

One thing is for certain.....if I had the manufacturer build the high heat tooling for this process....these would NEVER had come to market ! It would have cost many thousands right out of the gate

[Z4Murder]

This Is Amazing!

[JCz04Bimmer]

Subscribed.

I'd make the track version with extra cross-bracing and not removable. Definitely would love to see that!

[crfine88]

Wow, Thank you sir!

This is awesome, I'm in!!!

[inTgr8r]

Major props for your initiative on this project.
The talent we have on the forum continues to amaze me!!!!!!

[Caddyshk]

[r4gs]

'tis awesomeness. targa top ftw!

[robrwalker]

I am so excited I check this thread twice a day.

[Twisted Six]

Originally Posted by robrwalker

I am so excited I check this thread twice a day.

I feel your excitement ! pace yourself though....this is only in the initial work-up for the most part.

Building the high-heat tooling and associated molds will require some time in the details.

I'll post up news/details as they occur...all the way up to the prototype and install.

I'll test the unit fully and report as I go to keep those interested up to date.

[azadian2b]

If you plan on doing a removable option then why don't you look into a cold/low heat bend out of sheet acrylic/lexan option instead of high heat injection molding? The piece shouldn't need that much contour if you're building it into a removable frame to lock into a substructure. Then you would only need to make molds for the substructure/frame pieces. I'm just thinking off the design of a removable roof had on a past car.

As it is, you don't want a roof with too much contour (ie. the stock roof bubbles) because you might get weird lensing effects so you might not want to use the same contoured molds you're using for the CF roof.

Just my opinion, I'm very excited for this project.

[Twisted Six]

Originally Posted by azadian2b

If you plan on doing a removable option then why don't you look into a cold/low heat bend out of sheet acrylic/lexan option instead of high heat injection molding? The piece shouldn't need that much contour if you're building it into a removable frame to lock into a substructure. Then you would only need to make molds for the substructure/frame pieces. I'm just thinking off the design of a removable roof had on a past car.

As it is, you don't want a roof with too much contour (ie. the stock roof bubbles) because you might get weird lensing effects so you might not want to use the same contoured molds you're using for the CF roof.

Just my opinion, I'm very excited for this project.

I'm unsure where you picked up the thought that this clear roof was being Injection Molded ?

Perhaps you are confusing Resin Infusion, which is how I'll be doing the CF parts....but not the Poly or Acrylic portions.

Regarding the removal of the double-bubble design que's.....I personally feel that is one of the coolest lines of the coupes.But having a smooth roof could be considered...although I wouldn't want that on my personal coupe.

Will there be unusual lensing of the optics in those zones ? Perhaps.....but doing a shapeless convex (otherwise flat) roof might be quite boring...or at the worst lose personality.

It would certainly require a much thicker/heavier layer of product as well. The Double-bubble actually adds strength to the otherwise flexy shape.

I have two of the coupes steel roofs to work with currently. If you've looked/studied the substructure's enough....one will note they are twisty and flexy even made from steel.

Either way...molds must be built to hold current given tolerances for fit.

High heat molds must be used in that the Poly/Acrylic has to reach a specific temperature in order to take complete form accurately along with a vacuum environment due to the convex bowl-like shape and double-bubble accents.

I'll have one series of molds for the Clear roofs.....and a full other series for the CF components.

Yet another set for the interior headliners.