My FX-R Projector Retrofit Thread

[IRUNEDM]

This is awesome! Keep it up.

[AndrewBird]

Anyway, by your recommended calculation, I should be using 2400 RPM with my 1/2" end mill & 4800 RPM with the 1/4" one. So, some of the lousy finish is probably due to that. The other culprit was using a single heavy pass for all cuts since I figured I would be using this as a proof-of-concept part. What are the units of "sfm"? If it is inches per minute, I think I may have a hard time hitting 300ipm by-hand!

For the actual parts, my plan is to do cuts in 2 or 3 steps, with the final pass removing 0.005". Would climb-cutting that last pass yield a better finish? I have also read that using Kerosene will give a better finish than cutting oil; any thoughts there? I think that it is time to get out my 1000 page Manufacturing Processes text/bible & re-read the section on milling.

Thanks for the TAP link. I will check their stuff out!

SFM stands for surface feet per minute. It isn't a feed rate, it is a rating for the material of how fast it can be cut. do not confuse it with IPM (inches per minute), which is how feedrates are given. Here is more on it:

http://en.wikipedia.org/wiki/Surface_feet_per_minute

Leaving a 0.010 finish pass would be best. 0.005 is a little thin (roughly the thickness of a hair). Climb milling will give you a better finish, but only if your mill is rigid enough. It might chatter too much and cause finish problems. You will just have to test and see.

As far as oil goes, with a sharp end mill, aluminum doesn't really even need cutting fluid, however it can help. I generally just take light cuts (nothing more then 0.030 per pass) with no lube and slow feeds.

[dinanm3atl]

Definitely badass! I did a Morimoto Mini H1 retrofit into my E36! Love the lights! This will be awesome!

[bmwman91]

Thanks! The last few weekends have been busy with all sorts of stuff. This weekend is too. I am planning to machine the final pair of plates next weekend (2/25). Damn you, responsibilities!

[EVillalonRN]

I did the Morimoto mini H1 in depo lights. Way less cutting. I only had to fabricate tiny brackets. And it all seals up in the original buckets. I was in a rush when I did it, so I did not take any photos during the retrofit.

[E30-M3]

Any updates on this? I wanna see some more mill porn!

[bmwman91]

Haha sorry, been swamped with work & other stuff. My M42 died and I am waiting for a little delivery from Metric Mechanic to replace it with, and I finally got my shit together and am building some E30 MAF conversion kits. This WILL get done though!

[darvo]

In for a kit if you're willing to sell those!

[e30shmobberr]

wow awesome adapter!

[airkhin]

i really am looking forward to more updates on this thing. ;)

[bmwman91]

i really am looking forward to more updates on this thing. ;)

Haha yeah, me too. I am in Asia for work right now, returning this weekend. The next weekend will be spent installing a new motor and general car maintenance. Thereafter I will be machining out the adapters. The real challenge is still in building the molds to cast the weather seals. Seriously, does anyone here know where I can find a rubber cap with a 5" ID on one end, ~2" ID on the other and that is maybe 1.5" long? I would never run these without some sort of dirt and water barrier protecting the housings.

[bernzpeed]

you're best bet is go to walmart and find a round tupperware in that size. i'm sure you can find one.

[NC318e30]

As I read you last post concerning with the seal for some funny reason an idea popped in my head. Not to say its a good one or that I've even had more than a full minute to think about it but.... try looking at some different toilet plungers lol

[Evil-E]

I'm not sure what years or the actual dimensions but some of the earlier E46 xenon headlights actually had a rubber boot similar to what you're looking for. It's possible that they'd be close enough to the size that you're after and they'd be an OEM piece.

Awesome writeup btw!

[bmwman91]

As I read you last post concerning with the seal for some funny reason an idea popped in my head. Not to say its a good one or that I've even had more than a full minute to think about it but.... try looking at some different toilet plungers lol

Hey, you know I never thought of that! I will go see how close I can get, Nice idea!

I'm not sure what years or the actual dimensions but some of the earlier E46 xenon headlights actually had a rubber boot similar to what you're looking for. It's possible that they'd be close enough to the size that you're after and they'd be an OEM piece.

Awesome writeup btw!

Hmm, I'll have to snoop around RealOEM. Thanks!