Challenge Engineering is very happy to officially release its first aero part in to production. As some may already know, it has been long coming, but well worth the wait. We owe our initial thanks on this particular project to Myke (user: MyKmYk) with his Individual Atlantis Blue sedan. He commissioned this project originally after seeing our coupe concept trunk. Our commitment to producing a top quality part here in the USA and settling for only the best has finally resulted in a great product for the BMW community. Every Challenge part is designed in house, here in the USA. Much of the design, modeling and initial prototypes are done by myself. This ensures the best quality from step 1. All finish modeling, molds, and final products were also produced in the USA. We are fortunate to work with some of the best manufacturing partners in the country, if not the world. The particular facility we use to produce most of our aero parts also produces many parts and components for Indy Car, Champ Car, and Speed World Challenge proffesional race teams. I’d like to take some time to show you guys a snapshot of what goes into the design and manufacturing of an new part here at Challenge.

Stage 1:
Initial product idea and marketing plan is drawn up. Can we make this? Will people buy it? How might it look? Once we sit and talk about if it’s a good project we can take on or not, and vote yes, it’s on to the next step

Stage 2:
Design concept is sketched out on paper to see what the potential part may look like. Any aero advantages or requirements are also thought of at this time depending on the item. In this particular case, we had a design concept to follow from the coupe trunk design concept. We knew that the sedan trunk would follow in a similar style. We then move on to doing a physical full scale model on the car. This helps ensure the design drawn can even be done, as well as works with the cars design and body lines. We started off with a brand new trunk from BMW to ensure that all attachment points and holes are there. It also helps guarantee perfect fitment. It takes a good amount of time to build up the clay surface on a large part such as a bumper or trunk. Once you have about 20% more clay than you need, we then start roughing out the basic shape of the part. From there we begin using more delicate tools to get into the detail and final shape of the part. After we have the part smoothed and lines straight it is time to go to a different material.



Stage 3:
In order to be able to pull a mold from our master part, we must use a material more durable than the automotive modeling clay. We leave 50% of the clay on the car so we can make a reproduction of that part in foam, fiberglass, and body filler. Leaving the clay allows us to take measurements at key areas, so we can ensure the size, scale, and shape stays true and equal. Once the Fiberglass half is done, we take final measurements to ensure that it is symmetrical, then remove the other clay half and repeat this process.



Stage 4:
Final preparation and fine details are addressed in the fiberglass part that will be on the production part. Small details and lines are sharpened and checked. Once we are happy with the part, it is sprayed in primer and checked for symmetry and design details before final paint. Once painted, it’s off for molding.

Stage 5:
The mold process begins with checking for any imperfections in the surfaces. Any flaw in the master part, will show in the mold, and be imprinted in each part after that. All holes and possible hang ups are filled. The mold is divided up into and inside and outside skin just like the factory trunk. Once the mold is completed, the master part can be pulled, and the production can move forward.



Stage 6:
First test parts generally will not all be perfect. It takes a few items before you can perfect the formula. Some parts may require additional reinforcement while others may be able to have less. Special attention must be paid to areas where latches are attached or the hinges mounted. These areas will require metal inserts or extra carbon material. Each half of the trunk is laid up separately by hand before being placed in its vacuum bag for the resin infusion process. Each part is put under vacuum so that no air bubbles or pockets are present. The allows the resin to be drawn from one end of the part to the other with little waste and no extra resin content that adds unneeded weight to the part. Once each half is complete, they can be trimmed out for headlights, handles, locks etc. Once completed, they will be placed into the assembly fixture for bonding of the components and the skin to the skeleton.



Stage 7:
After the adhesives have cured and the part looks near completion, The part is checked for quality. A checklist of all treaded holes and details are looked over and marked off. The part is buffed to a gloss finish and then is off for packaging or to the paint shop to be prepped for paint or installation





The Sedan LCI trunk can now be ordered from Challenge Engineering USA, or any of its dealers. Februrary is a big month for us, as we will also be releasing the coupe trunk in the next week or so, followed close by the much desired Challenge diffuser. Please contact us with any questions you may have! sales@challenge-usa.com


DETAILS OF EACH TRUNK VERSION:

GT Carbon Fiber Race Trunk - All LCI Sedans

Designed, engineered, and manufactured in the USA, our GT carbon sports trunk is the perfect addition to your 3 series BMW. Each trunk is constructed by hand from 100% carbon fiber materials inside and out. Additionally carbon Kevlar is added in key areas for strength and rigidity while maintaining maximum weight savings. From the factory, all 3 series models come with a heavy steel trunk. Mass amounts of weight savings from the rear most part of the car can be achieved by swapping to a lightweight version. Not only will you see a difference in handling, acceleration, and chassis response, but a stunning appearance as well. The intergraded spoiler on the trunks edge blends seamlessly with the factory body lines to create a true OEM look with perfect fitment. The trunks spoiler edge will offer additional aerodynamic down force to the rear of the car with minimal drag created.

Specs:
Factory trunk weight: 38.5 lbs
Challenge - GT Carbon Race Trunk: 9.9 lbs
- OVER 28lbs weight savings! -

version pictured

GT Carbon Fiber Sports Trunk - All LCI Sedans

Designed, engineered, and manufactured in the USA, our GT carbon sports trunk is the perfect addition to your 3 series BMW. Each trunk is constructed by hand from carbon fiber materials on the outside skin. Additional carbon fiber is added on the interior fiberglass structure in key areas for strength and rigidity, and finished with a black gel coat. From the factory, all 3 series models come with a heavy steel trunk. Mass amounts of weight savings from the rear most part of the car can be achieved by swapping to a lightweight version. Not only will you see a difference in handling, acceleration, and chassis response, but a stunning appearance as well. The intergraded spoiler on the trunks edge blends seamlessly with the factory body lines to create a true OEM look with perfect fitment. The trunks spoiler edge will offer additional aerodynamic down force to the rear of the car with minimal drag created.

Specs:
Factory trunk weight: 38.5 lbs
Challenge - GT Carbon Race Trunk: 16.5 lbs (estimated)

Installed photos:




Challenge Engineering USA - Home

 

And you wonder why we invited you here! Look at this work! It's fantastic!

 

Amazing! I'm a big fan of your work. Good to have you on TS.

 

Absolutely incredible! Great work, guys!

 

amazing work, welcome aboard.

 

Thanks much for the kind words!