The 8 curves have been sanded by hand.
This is the model that will get milled out of aluminium



Here you can see that i've glued a 5mm alloy piece to the MDF board.


Afterwards i've used the copymill again to mill everything nice and easy...



Once everything was ready i found it rather *****. I didn't like the result because it was too thin.
So i took another 8mm aluminium piece en started all over again.
As you can see, i've used the original 4mm part as a mould for the new 8mm part.


To obtain the same design as the grill on the subbox, i had to work magic.
Remember this??? The difference between the holes.

First i made a board with a thickness of 8mm so that myuppermill couldn't flip over.

Then i've milled out the 2 parts. Here i've milled 3 mm deep.

 

Now this piece had the same look as the grill.





It took me about 8 hours to make this part.
Now it needs some more hours to sand and pollish it.
That's what they call: making an alloy piece..

I've created a crooked side on the back of the alu plate. This is because i'm going to work it into the polyester. This will make it easier to take out the piece.




Here i've made a carbon box for my Sony PSP.
The horse on top of the box is an original Ferrari logo.

 

i've polished the aluminium part.
Firt i've monted it on al MDF board to protect my fingers from getting burned.
this is the result after 2 hours of polishing.





Here you can see how it should like like when it is finished.
as i've said before: on the frontside of the crossovertray.



Then i started taking some serious risks.
The straight part needed to be "less straight" so i had to bend it.
Therefor i created this.

 

So, now the part is ready to integrate in the rest of the booth.
Now i need to make a piece to mount on the backside of the aluminium part. this will be made out of carbon.
I've milled the model out of a 3 by 22 mm MDF board
Afterward i had to mount them back to back.


This will be used as a mould.
I've made the thing so that i can use my 2 hands while working.

Here you can see that the part can spin.

I've used some paper tape.
Afterwards i've covered it with a layer of carbon en 4 layors of polyester.

 

Now that evering thing is dry, the mdf parts are no longer needed.
So i'll use a saw to get them out.
I'm not sure if it will work...
It's a risk i had to take.


I continued taking the piece out of the mould.
I had to clean it up a bit.


With an electrical saw i was able to remove the biggest pieces.


So now you see why i made the 2 holes in the board. Much easier to saw!
The rest was taken out by hand.

This is what it lookes like on the inside. In the middle you can see whe the 2 pieces of tape came together. after a few more layers of epoxy, it will look spotless.


Time to use my GIANT sandingtool.


On the other side i've sanded the curves of the allow part.


He're i'm using my router to mill out a piece of plexyglass.

 

The plexy will get mounted on the backside of the allow part.

This is how everything should look like in the end.





Don't go thinking that it's done! I planning on doing something special with the carbonpart, but i have to figure out if it is possible and if i have enough space to to it.
Now i going to make the front to mount on the crossovertray.

I still need to make a piece of plexy to mount on the rear of the carbon tray


Plexy mounted.

 

Here y ou can see how it will be mounted on the frontside


Here you can see the frontside of the crossovertray under construction.
I've made a board out of MDF with left and right exactly the same curves en mounted them in the trunk.


Afterwards i've filled it up with poly.
Once it was dry, i did the same on the left and right side.

 

I needed to adjust the backside of the poly part. Now it fits nicely and is just the way i wanted it to be.







Here you can see the crossovertray while opening.




Picture of the inside of the place where the crossovertray will be mounted in.







Next thing to do is shape the front of the tray so that is will fit for 100%.

 

It was pretty cold, but i found a way to keep me warm.
This is what my workshop lookes like after sanding on the tones of metallica's death magnetic.

As you can see, i've used a can of spraypaint to sand the curves.

Here's a picture of the finished part to fit on the front of the crossovertray.





On this picture you can see that it fits perfectly.

 

The carbon part that will be mounted on the front of the tray is sanded and ready to be clearcoated.






In the meanwhile everything is removed from the car, so that it can get a final touch .
The carbon is already covered with epoxy.






I've been looking at the crossovertray, and it misses something...
In the front you can see the lights that i will be mounting.