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BMW moves to plastic for some coupe body panels

04/28/2006, 11:51 AM

By admin

BMW has transitioned to using plastic front quarter panels (fenders) on its 2007 BMW 3 Series Coupe in order to save weight and increase durability. The weight savings is minimal — about 6.6 pounds — but it helps BMW achieve its much-touted 50:50 weight balance more easily. The new material also offers greater freedom in design, being easier to mould and shape than steel – an important factor giving the designer new freedom in the design process. BMW says the fenders are painted with the exact same paint used for the steel unibody and look the same as steel panels. In low-speed collisions, the new panels are also less likely to permanently deform. After the jump we have two images: one illustrating how light the new panels are, and another shows the difference between the sedan and coupe’s fenders (with the latter having a deeper character line)…

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04/28, 12:19 PM

posted by:

mammor

The fender’s so light a little girl can carry it! check it out lol

http://www.e90post.com/forums/showthread.php?t=18359

04/28, 12:23 PM

posted by:

JD

Whatever works!

04/28, 12:33 PM

posted by:

Mike

hey, what’s good for Saturn is good for BMW…

04/28, 12:34 PM

posted by:

Mike

edit: What’s good for a 1994 Saturn is good for a 2007 BMW

04/28, 12:39 PM

posted by:

///mach3

I still don’t see why other auto manufacturers haven’t done this.. I know the original fiero had the composite panels, and Saturns (scoff as you will) have ‘em – it keeps stupid door dings and minor bumps off the body – no more need for minor body shop work, or PDR, etc. As crazy as it may seem, plastic paneling FTW.

04/28, 12:43 PM

posted by:

TW

Works for me. Less rust also.

04/28, 12:43 PM

posted by:

JW

So does this mean BMW’s will actually be affordable now?

04/28, 12:46 PM

posted by:

Northeasterner

I am fine with plastic as long as it doesn’t compromise safety…

04/28, 12:49 PM

posted by:

Don

These plastic panels are probably more expensive for BMW compared to steel, given the rapidly increasing price of crude oil.

04/28, 1:11 PM

posted by:

Mike

one problem with the door dings and stuff: Saturn had their color molded in, BMW is painting theirs…so yes, you will still have the door dings.

04/28, 1:21 PM

posted by:

SR

But I bet a “ding” in the paint will be harder to get with plastic behind the paint. The plastic will bend more and not chip and dent.

04/28, 1:38 PM

posted by:

E M

Saturn colors were not “molded in”. They only had a different tint base for light/dark colors, I think. I’ve seen the back of a Saturn panel, and it is not the color of the car.

Plastic does REDUCE dings, but they will still mark and deform, but it takes a lot more force. GM had a gold-mine with the process they developed with the Fiero, and later the Saturn, but again failed to refine it, and educate the consumer about all of it’s properties and compromises. (like large panel gaps) I love seeing an old Fiero or Saturn with the wheels falling off but the bodies look like new…where my new Beemer looks like its gone through the duck-shoot at the local carnival when I park it at the airport.!

04/28, 2:03 PM

posted by:

Northeasterner

E M – it’s “Bimmer”, not “Beemer”. The term “Beemer” refers to motorcylcles.

04/28, 2:59 PM

posted by:

tosta_mista

The ‘designer liberty’ is a crappy excuse to try to reduce costs.

“These plastic panels are probably more expensive for BMW compared to steel, given the rapidly increasing price of crude oil”

No way, steel isn’t cheap at the moment and also it needs to be pressed.

04/28, 3:52 PM

posted by:

Jon

Northeasterner is correct.

Jon.

04/28, 4:28 PM

posted by:

junkie

Other BMWs (and many other cars) have already been using plastic bodypanels, so why exactly is this noteworthy?
/Just askin’

04/28, 5:09 PM

posted by:

Don

“No way, steel isn’t cheap at the moment and also it needs to be pressed.”

You’re right steel isn’t particularly cheap at the moment at ~$600/ton. That compares to about $580/ton for crude oil (assuming 7.333 barrels/ton). But the chemicals used to make these plastics are just a small fraction of that crude oil. To refine the oil and synthesize plastic will cost way, way more than the price of steel.

Plus the fact that steel can be pressed is actually a plus over plastic. Pressing parts is much more efficient than casting, molding, and setting plastic. Molding simply can’t produce the same number of parts per hour. Plastics are a time consuming process compared to simply stamping steel. And time equals money. Plastics will be more expensive.

04/28, 5:21 PM

posted by:

jm

Saturn’s were also built on a spaceframe that placed no load on the doors and f/r fenders. Most cars actually integrate steel body panels into their structure and rely on them for strength and body structure. Also note most plastics are “thermoplastic” and weaken, soften, and expand with higher temps. BMW may have improved on this to a degree but it is still an issue and even more difficult with larger parts like doors. This leads to larger panel gaps, increased wind noise and more drag.

04/28, 6:00 PM

posted by:

Asher

Plastic body panels suck – of course these are some type of composite but still, there’s only 1 main issue I have with them > look at 2 cars in person next to each other, one with steel-bodied panels and the other with plastic with the exact same paint job/color etc. If you don’t notice the difference, then you’re likely not an auto enthusiast and an LLN reader.

Any car enthusiast knows quality when they see it and could tell you that painted plastic body panels always look cheap and plasticky – imagine that. Painted steel appears solid and tank-like. For a good example, look at Mercedes models – the old E-class vs the current one or the new C or E-class vs the SL. Painted steel ALWAYS looks better.

Of course, in this case, it is very MINOR use and it is done to get 50/50 perfect weight distribution and I guess some things have to be sacrificed on the new 3 Coupe in order to gain other cool new features like that new 6-speed high-tech Automatic box…

04/28, 11:49 PM

posted by:

gsh

who cares about 50/50 weight distribution. the evo8/9 has a 60/40 bias and will still burn all (hmm i think the FQ400 can but we dont get it here in the US) BMWs in the straights and corners and i really do mean ALL…please

04/29, 12:45 AM

posted by:

Asher

please yourself – go ask 50 random auto enthusiasts “Youve won a choice of 2 cars, the Lancer Evo 8 or an e46 M3,” I guarantee at least 48 take the M. Dont reply until you go do it and come back w/real-world results…

04/29, 1:19 AM

posted by:

gsh

you obviously have no clue about the evo8 (much less the FQ400). its clear bmw has their wool over your eyes but hey, thats ok, i respect the e46 m3. if the question was rephrased “which would you take to win a race? the evo8 or the e46 m3?” and show me a person who actually races that would take the m3. dont bother reading up on cars unless you know about more than just 1…

04/29, 11:23 AM

posted by:

Asher

gsh, I respect your opinion but my question didnt regard which was a better Track/Race car – this thread is about a standard 3-series coupe with real-world drivability and your initial post simply states that a Lancer Evo could wax it on a track – well of course it could, thats why I brought up the M3 comparison.

The Evo is a fine, sharp-edged cutting tool with ultra-low weight and a big turbo-4 essentially created with 1 goal only in mind, the track – I would simply compare it more directly to a souped-up rally car like its classic rival, the Suburus, in which the materials, build costs and PURPOSE are roughly equal, than a 3-series coupe, that’s all – best regards, Asher

08/17, 11:05 PM

posted by:

Jeff Jones

Asher,

What looks better after a few years of real world use, a dent free exterior with slightly larger panels gaps, or tight panel gaps and dings all over the exterior? I’ll gladly give up some precision in exchange for a dent resistant body.

 
 
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