dori_86
30th April 2006, 06:49 PM
Hey I just thought I would do a rewrite up of my weekend project
SECTION 1 ---- Fixing the bumper
SECTION 2 ---- Making the Front Lip
SECTION 3 ---- Painting
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
SECTION 1 ---- Fixing the bumper
This is the stock bumper, which I got for $40 -cheers ae86dave
http://img133.imageshack.us/img133/4272/10002174in.jpg
http://img135.imageshack.us/img135/1082/10002182qn.jpg
There was some over spray on the indicators so I just used a bit of turps (Mineral Turpentine) to clean up but I didn't work all that well so I turned to using 800 grit wet and dry sand paper.
http://img137.imageshack.us/img137/6451/10002242fv.jpg
I sanded them with a bit of water, I will later spray these will clear coat to give back the original look, u can buy some special stuff to make ur lights shiny again but cost more than a can of clear coat spray paint http://www.ae86drivingclub.com.au/forums/emoticons/tongue.gif
With the bumper I sanded the whole bumper with wet and dry 800 git paper but i didn't use any water as the bumper is rough surface anyways so un less it is smooth i would suggest not using water.
http://img139.imageshack.us/img139/958/10002275zr.jpg
The bits on the inside of the bumper had been hacked off with a hacksaw. So they were sticking out a bit, so to get them flush with the rest of the bumper, I first used a hacksaw with an adjustable angle to help get closer to the bumper, then I used a metal file, then some low grit sand paper **cant remember but it was very rough** http://www.ae86drivingclub.com.au/forums/emoticons/tongue.gif, I then preceded to use 800 grit sand paper to get a smoother finish
http://img141.imageshack.us/img141/2540/10002302zq.jpg
My bumper had been in a previous battle with an unknown object so it was “dented in" and ripped to fix this I used two flat head screwdriver to pull the split outwards (if that makes sense?) I then use a Stanley knife to cut off the little “dags" of plastic and then sanded them I then pushed the split together to create a flat surface on the front.
I then used some gap filler/tile filler (cant remember what one it was but it was just some I had lying around in the shed) this was purely put on to give it some additional strength.
http://img98.imageshack.us/img98/9097/10002348fg.jpg
http://img96.imageshack.us/img96/9516/10002358pd.jpg
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
SECTION 2 --- Making the Front Lip
I went down to the local hardware shop (Bunnings) to purchase some lawn edging. I bought the 100mm high edge
NOTE
I'm not sure if this sized edge will scrub on lower cars as I haven't put it on my car yet and I have king spring which will be OK but I'm unsure if it will be OK when I put my new coilovers in http://www.ae86drivingclub.com.au/forums/emoticons/tongue.gif
http://img101.imageshack.us/img101/1310/10002373gt.jpg
I also bought some fancy black pop rivet to use but they didn't come in a big enough size and as I didn't want to used galvanised ones, I bought some self tapping metal screws (remember not to buy wood ones as they would probably be to harsh and could possibly tear ur bumper!)
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/101397.jpg
After buying all this stuff I decided to trial fit it to my car using simple electrical tape, I cut the lawn edge into I think a size of roughly 190cm but don't quote me as I'm guessing from memory.
http://img239.imageshack.us/img239/466/10002447ne.jpg
http://img141.imageshack.us/img141/6691/10002466pu.jpg
This is my attempt with pop rivet but the weren't strong enough to deal with the pressure of the bending at the edge of the bar because they were too small
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/101400.jpg
This is about ¾ of the screw process
http://img148.imageshack.us/img148/7623/10002511ow.jpg
NOTE
Remember to drill wholes first which r smaller than the screws u are putting in!
HIGLY RECOMMENDED
You may also have to make backing plates for the screw to screw into, just to give it some extra strength, I just used some scrap thin sheet metal which I cut into little rectangles which I then drilled holes into them. On a side note I did this after screwing the to pieces on plastic together and the realising it probably wasn't strong enough
WITHOUT
http://img161.imageshack.us/img161/1693/10002525hh.jpg
WITH
http://img84.imageshack.us/img84/3981/10002591vy.jpg
ALL SCREWS IN
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/101404.jpg
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
SECTION 3 ---- Painting
To do the painting of the bumper I used 800 grit wet & dry sandpaper but didn't use any water, as it is a rough surfaced bumper anyway.
I purchase some special “Bumper Bar Primer" and “Bumper Bar Black Paint" as it contains a special product to help with the flexible nature of the Bumper Bar
First Coat of Primer
http://img101.imageshack.us/img101/6297/10002575yg.jpg
Second Coat
http://img239.imageshack.us/img239/6721/10002601pb.jpg
I'm yet to finish doing the coats of paint as I'm writing this up while I'm waiting for each coat to dry http://www.ae86drivingclub.com.au/forums/emoticons/tongue.gif
I will post more pics when done
SECTION 1 ---- Fixing the bumper
SECTION 2 ---- Making the Front Lip
SECTION 3 ---- Painting
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
SECTION 1 ---- Fixing the bumper
This is the stock bumper, which I got for $40 -cheers ae86dave
http://img133.imageshack.us/img133/4272/10002174in.jpg
http://img135.imageshack.us/img135/1082/10002182qn.jpg
There was some over spray on the indicators so I just used a bit of turps (Mineral Turpentine) to clean up but I didn't work all that well so I turned to using 800 grit wet and dry sand paper.
http://img137.imageshack.us/img137/6451/10002242fv.jpg
I sanded them with a bit of water, I will later spray these will clear coat to give back the original look, u can buy some special stuff to make ur lights shiny again but cost more than a can of clear coat spray paint http://www.ae86drivingclub.com.au/forums/emoticons/tongue.gif
With the bumper I sanded the whole bumper with wet and dry 800 git paper but i didn't use any water as the bumper is rough surface anyways so un less it is smooth i would suggest not using water.
http://img139.imageshack.us/img139/958/10002275zr.jpg
The bits on the inside of the bumper had been hacked off with a hacksaw. So they were sticking out a bit, so to get them flush with the rest of the bumper, I first used a hacksaw with an adjustable angle to help get closer to the bumper, then I used a metal file, then some low grit sand paper **cant remember but it was very rough** http://www.ae86drivingclub.com.au/forums/emoticons/tongue.gif, I then preceded to use 800 grit sand paper to get a smoother finish
http://img141.imageshack.us/img141/2540/10002302zq.jpg
My bumper had been in a previous battle with an unknown object so it was “dented in" and ripped to fix this I used two flat head screwdriver to pull the split outwards (if that makes sense?) I then use a Stanley knife to cut off the little “dags" of plastic and then sanded them I then pushed the split together to create a flat surface on the front.
I then used some gap filler/tile filler (cant remember what one it was but it was just some I had lying around in the shed) this was purely put on to give it some additional strength.
http://img98.imageshack.us/img98/9097/10002348fg.jpg
http://img96.imageshack.us/img96/9516/10002358pd.jpg
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
SECTION 2 --- Making the Front Lip
I went down to the local hardware shop (Bunnings) to purchase some lawn edging. I bought the 100mm high edge
NOTE
I'm not sure if this sized edge will scrub on lower cars as I haven't put it on my car yet and I have king spring which will be OK but I'm unsure if it will be OK when I put my new coilovers in http://www.ae86drivingclub.com.au/forums/emoticons/tongue.gif
http://img101.imageshack.us/img101/1310/10002373gt.jpg
I also bought some fancy black pop rivet to use but they didn't come in a big enough size and as I didn't want to used galvanised ones, I bought some self tapping metal screws (remember not to buy wood ones as they would probably be to harsh and could possibly tear ur bumper!)
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/101397.jpg
After buying all this stuff I decided to trial fit it to my car using simple electrical tape, I cut the lawn edge into I think a size of roughly 190cm but don't quote me as I'm guessing from memory.
http://img239.imageshack.us/img239/466/10002447ne.jpg
http://img141.imageshack.us/img141/6691/10002466pu.jpg
This is my attempt with pop rivet but the weren't strong enough to deal with the pressure of the bending at the edge of the bar because they were too small
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/101400.jpg
This is about ¾ of the screw process
http://img148.imageshack.us/img148/7623/10002511ow.jpg
NOTE
Remember to drill wholes first which r smaller than the screws u are putting in!
HIGLY RECOMMENDED
You may also have to make backing plates for the screw to screw into, just to give it some extra strength, I just used some scrap thin sheet metal which I cut into little rectangles which I then drilled holes into them. On a side note I did this after screwing the to pieces on plastic together and the realising it probably wasn't strong enough
WITHOUT
http://img161.imageshack.us/img161/1693/10002525hh.jpg
WITH
http://img84.imageshack.us/img84/3981/10002591vy.jpg
ALL SCREWS IN
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/101404.jpg
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
SECTION 3 ---- Painting
To do the painting of the bumper I used 800 grit wet & dry sandpaper but didn't use any water, as it is a rough surfaced bumper anyway.
I purchase some special “Bumper Bar Primer" and “Bumper Bar Black Paint" as it contains a special product to help with the flexible nature of the Bumper Bar
First Coat of Primer
http://img101.imageshack.us/img101/6297/10002575yg.jpg
Second Coat
http://img239.imageshack.us/img239/6721/10002601pb.jpg
I'm yet to finish doing the coats of paint as I'm writing this up while I'm waiting for each coat to dry http://www.ae86drivingclub.com.au/forums/emoticons/tongue.gif
I will post more pics when done