Tozzy

Thought I should share with you my work with putting CF on the rear diffuser. I just love the looks of CF so I couldn’t resist testing it out.

When I got the trailer hitch for the M5 it came with the diffuser primed only so I had a choice of leaving it to a paintshop or having some fun while trying to get the carbon fibre look J

The job is quite easy but time consuming and I did a lot of research before I shopped for the stuff needed for the job. Here is what I got together for the job:

• Epoxy base with hardener, Marine epoxy with low viscosity to penetrate the carbon fibre and to flow out easily to get a smooth surface.
• Paper cups, wooden spoons and cheap brushes that don’t loose any “hair”. All these can only be used once so don’t go buy any fancy stuff for this.
• 2 Clearcoat spraycans for the final finish, the Epoxy can be polished to a surface that looks like glas but it doen’t like UV light so a protective clearcoat is required.
• Lots of sandpaper: 180, 240, 400 and 600 grade wetsand paper, same as you use on carpaints.
• Scratch Remover(I used Turtles but any hard rubbing will do), fine rubbing and 2 component paint sealant.
• Carbon fibre weave, preferably in a size that will cover all of the part without needing to put it side by side (will not look that great)
• Razor knife, to trim the edges from Epoxy and CF.

Ok, so here’s what I did:
First day: Take a heavy duty scissor and cut the CF weave so it’s about 1cm( ½ inch) larger than the panel that is to be covered.

Then mix about 50ml (2 ounces) of epoxy with Hardener and apply it to the plastic panel evenly with a paintbrush. Then tenderly lay the CF Weave on the wet epoxy and be careful getting it on straight so the pattern doesn’t wobble or the weave get dislocated which won’t look good. When you are satisfied with the alignment of the CF Weave, gently press it into the epoxy with your hands. This is quite messy and you should check on the Epoxy can if your brand is toxic, if so wear gloves, my brand was nice to my lungs and hands.

When you have pressed all over the CF you apply another layer of Epoxy ontop of the CF weave, don’t apply too much just cover it all again and smoothen it out with the paintbrush. Too much Epoxy will just flow towards the lowest point and build a thick layer there. Now leave it over night to harden.
Second day: Take the razor knife and carefully cut away the epoxy/CF that’s over the edge, sandpaper the edges so they get smooth with 180 grain paper.

Apply another layer of Epoxy ontop of the hardened epoxy from yesterday. Do not sand the epoxy yet even if it’s uneven, you have to get some thickness in the epoxy first or you will be sanding the CF Weave which probably won’t look nice.
Third day: Another layer of epoxy and in my case this was enough to be able to sand it nice and smooth with 180 grain sandpaper. After that sand it again with 240 grain paper before the first clearcoat layer.

Fourth day: Check the paint surface and sandpaper it again with the 240 paper if there are large “humps” that need flattening out otherwise switch to the 400 grain wetsandpaper and sand the surface really smooth before applying the next clearcoat layer.
Fifth day: Wetsand the clearcoat with 600 grain paper and apply another clearcoat layer.

Sixth day: Wetsand the clearcoat with 600 grain paper and apply another clearcoat layer, this to get a thicker clearcoat that will hold better against rocks and dust.
Seventh day: Time for the final finnish, Start with the Hard rubbing(Scratch Remover) and work it on until you get a shiny result. Then switch to the fine rubbing and work it in for an even shinier surface. And as a final finish you could use your favourite car wax but I used the same 2 component paint sealer that I have applied to the rest of the car. It ended up with a mirror shining gloss that I am very happy with. After this it is ready to be installed.


My biggest problem was that I did not have a paintbox so tiny dust particles were all over the paint and had to be sandpapered and polished extra much to get a even surface.

Hope this inspires some of you to try this out, it's alot of fun and looks great

Laidback

u da man thanks for the info...

cableguy

Fantastic write-up, thanks for sharing.

I have been thinking of doing something different to the rear of my car, and was thinking along the lines of painting it a slightly lighter shade for visual effect, however after seeing the results of your handiwork I just may have to rethink my modding.

C.

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2003 996 GT2 - Brutal...

Anzir

WOW! I saw the thread title and thought it was a DIY install of a carbon fiber part.. but this.. wow. That's pretty cool. Great write-up and photos!!

mfizza

wow u have skill very nice job impressive to have true talent

EM5PWR

looks good...what do you tow with a M5 ?

MCarRacr07

WOW...looks great Two questions though:

1. What size tires/rims are you running they look great!
2. Where do I send my rear diffuser so you can give it the CF look

Nice Job
Regards
MCar

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MCarRacr

89 M3 (Track Car) SOLD
00 M5 (R.I.P)
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06 330xi (Son's Car Now)
08 328xi(New Arrival)
95 M3 (Track Car)
08 M3 (lil Beast)

Rocket M5

Nice Job!!!

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Clem

Amazing result and great write up

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Fiber-Design

Very nicely done!... Good Job... We use similar process... we just choose different kind of resins...
Looks great!

Mcar.... we do provide that service.

Callero

Snyggt!

Looking great man, I just know I'd screw it up tho :-/

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2002 ///M5 - Carbon black "sleeper"

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