Custom S4 front lip project, 56k make a samich
 

well, i've planned for a bit to try to make a custom front lip for my S4. like most, im good with my hands on a car, and low on cash so i figured the project would be fun and challenging.


it starts off that at work one day i was out by our bodyshop ( I work for a Mazda dealer). i was going over in my mind on how to make a mold for a front lip, what i would use, etc. well, i looked over at some scrap bumpers from collisions and spotted a rear bumper cover for a 5 series BMW. the top part of the cover looked almost to perfect for the project i was thinking of.

so i asked one of my buddies to cut it up for me, requesting the top portion of the bumper. later on that day, he got it for me.

the top portioned was separated from the rest of the bumper by a trim molding. that left a perfect lip at the top.

http://i707.photobucket.com/albums/w...g?t=1252293081

http://i707.photobucket.com/albums/w...g?t=1252293104



so after some brain storming today i decided to dive into the project. i removed the factory front lip and compared it to the trim piece. not too far off, just some measuring and modification, i believed i could actually make it work.

http://i707.photobucket.com/albums/w...g?t=1252293262

now began the modding. at first i cut the trim in half. that made it easier to work with as far as molding with a heat gun, and mounting.


after holding the piece up to the car, initially i can see where to start. i had to make the sides of the trim piece flat and the top of the trim more of a 90 degree shape


http://i707.photobucket.com/albums/w...g?t=1252293417


you can see how much i had to bend and shape the trim with a heat gun and a little muscle.

http://i707.photobucket.com/albums/w...g?t=1252293513

http://i707.photobucket.com/albums/w...g?t=1252293536



again, back and fourth to the front of the car to bend and test fit. it actually became better with time. a little more heat and test fitting.

http://i707.photobucket.com/albums/w...g?t=1252293606

http://i707.photobucket.com/albums/w...g?t=1252293626

i didn't take pics but i held the stock lip inside of the trim piece to get an idea of where i need to notch areas out for low hanging fender bolts, and where the mounting screws needed to go.


after some measuring, i tapped the holes, but elongated them so it had some adjustment (will add more pics later of that).


heres some pics of the trim mounted.

http://i707.photobucket.com/albums/w...g?t=1252293893

http://i707.photobucket.com/albums/w...g?t=1252293947

http://i707.photobucket.com/albums/w...g?t=1252293967

after drilling the rest of the mounting holes and more test fitting and trimming i started on the other side. same process pretty much.


at one point in time i had both trim pieces side by side to make sure i had the same bends and shape. i think im pretty damn close just using a heat gun and muscle.


the hard part was getting the side of the trim and the front to bend correctly and look aesthetically correct.

http://i707.photobucket.com/albums/w...g?t=1252294160


i think it came out all right

http://i707.photobucket.com/albums/w...g?t=1252294215

http://i707.photobucket.com/albums/w...g?t=1252294237

heres a pic from above. it comes out almost the same as the top of the bumper. now i measured the factory lip. i was about 1/4 to 1/2" drop down from the cover itself.

this trim piece drops the front and sides 1.75" down and 3" out front. not too bad, almost the same as the Corksport lip.


after more trimming and test fitting i followed suit with the driverside. of course a little more heat and bending i got it to look like the passenger side.


here's both sides mounted up.

http://i707.photobucket.com/albums/w...g?t=1252294718


http://i707.photobucket.com/albums/w...g?t=1252294739

http://i707.photobucket.com/albums/w...g?t=1252294766


http://i707.photobucket.com/albums/w...g?t=1252294785


now, the problem is getting both pieces fused together. im thinking of either getting a strong 2 part epoxy for plastic, plastic weld, etc. thats something i'll tackle when i get back to work this week. the cool thing is, is that i can add to the lip and use it as a mold for a nice fiberglass/carbon copy. the options are endless.


i don't think it turned out too bad for a DIY lip project. a couple of hours and a snack break, i think it was worth a shot.

more to come when i get it put together and painted.


Comments are welcomed.

Wow. That's prettyt cool. Light years ahead of the home depot lip lol. That should turn out nice with paint.

this would compliment a lowered S4 easily. looks good keep it up.

Looks pretty good. A+ for ingenuity!

Nice :icon_tup:.

take the lip back to your body shop and let them use structural urethane to bond it together.

I say paint it and run it, looks good.

With a little finesse it will look good! I like how your thinking outside the box.

Fantastic. Looks great.

I have been wanting to do sort of an air damn instead of a lip up front, but the S5 has a recessed opening for airflow to the radiator, which makes it a bit more challenging than the S4.

Thanks for all the kind, and motivating compliments!



yeah, the Home Depot lip is just waay to underclass sometimes. some people can make it work, but its not for me. at least i have BMW parts on my car right?! lol. i can't wait for a drop.

I've only owned the car for a month and already im tired of NO S4 lips being offered at all. i mean, its not a horrible bumper and aerodynamically speaking, it shaped better for cooling and air diversion on a track.


i would still like to reinforce it with some fiber glass, but for the most part, the ABS plastic is like an 1/8th" thick all through the lip. its actually less flimsy then the factory lip which is nice.

Maybe a couple of Z type brackets to mount the lower portion of the lip back up to structure.


i'm taking it to the body shop this week and see what they can do for me. im pretty sure the bonding agents that they have will do the job. now, should i do gloss black or factory Sunrise Red?....

Sunrise red for sure. If you match the paint, it'll look more like it was made for the car. In my opinion the best body mods enhance the look and if done right, look like they could have even come with the car. I think you can get that look the way you're going.

spray can = seriously its gonna get chipped/scratched so no need to spend $$ on painting a lip.

i have thought about matching the paint and body coloring it. the only downside of course is cost.


rattle can keeps it cheap and simple, in which this project was totally on that side. but if i do make a killer mold off of it and its in way better presentable shape, i'll paint it the body color.


now i just have to get it out of the garage and take some pics lol.

I think black is a good choice for the lip, the problem with a older red car is that the lip will not match the car that good, meaning if you have original paint on the rest of the car it will be tough to get a color matched lip to match 100%.

black eliminates the whole thing.

here is my lip on squeeb's red car, he left it black.

http://i15.photobucket.com/albums/a3...100_2507-1.jpg

http://i15.photobucket.com/albums/a3...r/100_2512.jpg

^^sweet pics! i like that its an S5 lip, but again, its nothing specific for the S4.


i have been thinking of making a nice mold of this lip, maybe with a little more add ons. hopefully i can make something of it.

btw, definitely black. i did think about the problems of matching the shades of red. not worth it.

if your thinking of making a mold to sell them I would give you this advice: plenty of people will claim they want one, but when it comes time to pay up they become very scarce.

looks great

I approve!

looks great man. hope you make copies if so put my name on the list to get one

i for sure understand that. even if i end up making them, they'll be a limited run. nothing to make any decent supplemental income from.

im just trying to give the S4 bumper some love, lol.

I'm pretty sure there are two "M"s in "Sammich".

Unless you're from Yurp and use the "metric M".

ya, i would have switched it but i can't edit it anymore. fail>ME :dunno: