Ok. This takes a long time to write, so bear with me.

Here is what you probably want if youre referring to this thread. These are real pics of my car with this mod finished.





Before you start you'll need:
Fiberglass mat
Particle respirator (mask thing)
4 pairs of latex gloves
Resin and liquid hardener
Something to cut with, (die grinder and dremmel)
"L" brackets from home depot
Some kind of body filler
That clear plastic packaging tape. Yes, the fat one. Not to be confused with scotch tape.
Celebratory beverages.

Arite. Here it is.

1. Take off the bumper cover. Do not forget about your bumper lenses.

2. Remove the bars that go across the headlights and there will be two big screws on the hard safety bumper that go across those holes. Remove those also

3. Take off the metal brackets from the top of the bumper cover. (LEAVE IN THE SIDE BRACKETS WITH THE SCREW THINGIES IN. TAKING THESE OFF WILL SUCK BADLY LATER.)

4. Remove the ftp lenses and foam things

5. Discard the shorter metal pieces from the upper support frame (there should have been 3 pieces there to begin with)

6. Mark the front of the bumper cover where you want to cut with a pen or something

7. Take a die grinder or something and cut the bracket backing part that usually sits behind the ftp lenses.

8. You should now have completely empty ftp lens holes.

9. Now stare at your bumper. This is the point of no return. Yes. It really is.

10. Cut the part that you marked earlier. I just continued the lines up from the lens hole. Do not use a dremmel cutting wheel for this. It will break because the part that youre cutting will melt and grab hold of the wheel, breaking it. Very wasteful.

11. Ok, So now you should have 2 big holes in your bumper cover.

12. Cut the metal frame thing accordingly

13. Place the bumper cover on the ground, the colored part facing up.

14. Take the packaging tape and form the walls of the part that you want to add. Make sure you do this from the outside. If you do this from teh inside of the bumper, it wont work.

15. Support with the L brackets

Ok so now you have a makeshift mold.

16. Cut and place the fiberglass in the part that you want it. make sure there is enough excess hanging over and into the inside of the bumper.

Wear latex gloves for this part

17. Brush the resin generously all over the fiberglass.

18. Poke the bubbles with a small screwdriver while its still wet.

19. Now let it dry overnight

20. If its dry, remove all the tape.

21. remove all the spots that the resin ran over accidentally.

22. Place the bumper back on the car

23. Sand the hard corners with some heavy grit sand paper.

Wear gloves for this part also.

24. Take some body filler and smoothe out all corners that you want ot be rounded.

25. Smoothe out the parts that arent level too.

26. Take sand paper, dremel and other sanding stuff and sand the filler.

27. Fill all the little holes that the bubbles left over from the filler.

28. Sand. and trim parts that hang over too far into the car with a cutting wheel

29. Wash up and open celebratory drinks.

30. Paint.

 

very nice write up. We should save this on the archive.
Post more pics later on.

 

Damn nice job

 

Looks like an 80 z car.

 

The dark areas around the cutouts arent a lip that goes up, its just the camera angle and a part that hasnt been polished yet

 

that looks really good.
good job!

 

One more question: Any new dark areas because of this? (ie. are the sides still well lit? (it looks like it could really restrict the field of view as a result... (to small of an angle inside))

 

Looks nice, but please let us see this summer when the bumper and fiberglass heat up and crack. They have substantiallt different rates of expansion and contraction. You probably should have used a product designed for repairing bumpers

 

I will attest to not using a rotary tool to remove material off the bumpers. I did last night and used ATLEAST 20 cutting wheels (I have a big box of them) on my front end project (nothing like this). I have all sorts of little ******* cuts all over my arms from when the blades shattered. Oh well

And I agree, you should have used the proper material for our bumpers and not fiberglass. I forget whats it called, look up a thread I made about FTP lenses, someone links a site that talks all about it.

 

I did ts the norton site, even has vids on how to use it

 

You know, I was trying to think all day what that reminds me of, and now I remember... 3rd gen Camaro. And with that being the case, it probably should light up the road ok, even as far recessed as it is. It will probably have less light on the sides, though. I don't think that can be avoided without moving the lights themselves farther forward somehow.

FWIW, the 924GTS had a similar setup, except they replaced the headlight covers with plexiglass and moved the lights up even with the bottom. More like the original AE kit for the FC, I guess.

Ren

 

BTW, you have a head-on shot of this? I bet it looks a lot better from the angles you shot it than it does from the front...

Ren

 

And what IS the proper material to use? What is wrong with what he used?

 

Hey... it was just a boredom project. If you guys dont care for it, so be it. I'm not gonna keep this front for much longer as im going to start a new project hopefully this summer. I really havent seen fiberglass simply crack from normal heat - i live in the bay area (it really doesnt get too hot). The filler might crack, but i care not. Ill post a pic more towards the front in a bit. ill take some more pics from directly in front.

 

It actually looks decent from straight on. ill try to get some pics up soon. i still have to take them. The reason why i didnt take some from directly in front is because there was a car parked there and i couldnt squeeze in back enough to get a decent shot

 

Nice job chaos... Wanna do another one.. aww cmon I am close enough!
*lol*
- James

 

If i help you on yours, we'll have to research the "correct ingredients" as said above. i dont wanna do an almost job on someone else's car.

 

Good job dude, I like it

 

kinda looks like a late 80's early 90's Camaro front lights except just one instead of 2.

Not bad looking though.

 

so i assume you made it so the lights dont pop up right?

 

That's a good question! And if not, How is the night visibility?

 

Like I said: You did a nice job, you just used the wrong materials. Here is a link:

www.paintucation. com DIY Auto Painting Board

www.nortonautomotive.com/...howto5.asp Plasic Bumper Repair videos

I am just pointing out the incorrect choice of materials so someone elese does not make the same mistake

 

Looks good, but does remind me of an '80's Z car .

 

yeah you need to fill in the head light covers with the hood now, though it does look pretty good...

 

Great Job! I like, me think me make it on mine.

Al