yet another custom bumper thread Options

[BloodyStupidDave...]

Given the interest in Malpaso's bodywork thread, I thought I'd share some pictures of my work in progress.

This project was inspired by two threads last year, doGGy / Marchius's front bumper project and another project whose details I can't currently find. It was from the summer 2007 and had pictures of a gt4 grille being cut into an aftermarket (vader I think) bumper.

I think that I started my project before Malpaso started his (I started in August I think), but I've been doing the work myself during the weekends (without a heated workshop) plus this is the first time I've tried any bodywork mods on this scale so my progress has been much slower.

Like Malpaso, I used a damaged GT4 bumper and plastic welded it to the st202 bumper. One thing that Malpaso didn't mention was that the two bumpers are made from different plastics. The GT4 bumper is much more rubbery.

I decided to be a bit more adventurous than just doing the grille. I deleted the st202 indicators (turn signals) and relocated that functionality into the JDM headlights and made the side ducts larger as discussed in this thread.

I found it really hard to judge just how big to make the side ducts. When looking at it on the actual bumper, the way I drew them in the above thread just looked too over-the-top. I think I've got it looking about right on car.

There is still some work to do. It still needs final coats of paint, clearcoat and buffing. The ghetto upper grille is temporary - I should have the proper one on Monday with luck. There is a little repair work to be done on the mid grille, plus I need to finish modding the poly impact absorber so that the mid grille isn't purely decorative. And I have yet to manufacture the grilles for the side ducts.

[lubu]

exellent work..looks amazing...No im serious.It looks good.

[manphibian]

That's going to be awesome! Good work

[malpaso]

I'm glad to see how my project would look like with that GT-four bumper vent in the middle I have not used

[Shink]

Liking this a lot

How did you make the lower grill bars? Got pics of that process?

[BloodyStupidDave...]

How did you make the lower grill bars? Got pics of that process?

The grille bars are very simple - just U-profile aluminium tube bent to a constant radius then spray painted. The most difficult part is working out the exact 3D angle to cut each end (and yes, each row is at a different angle on the X-Z and on the X-Y plane).

Any decent metalworkers' workshop will be able to create a piece for you. However, I cheated. I acquired two DB9 grilles (one from my local scrappy, one from ebay) and pulled them apart. The radius isn't quite right if you look at it from the wrong angle (you can see that from one of the photos above) but overall I'm pleased with the end result.

If you go the metalworkers' route, you could just use metal spacers between each row and long bolts to hold the whole thing together, or weld the rows onto vertical posts (aluminium welding needs specialist kit, but U-profile is available in steel which might be an alternative). If you go the DB9 route, you can simply cut and reuse the posts that were part of the DB9 grille.

I'm afraid I don't have any pictures of either the grille or the bumper at the moment. I took lots over the months, but my hard-disk died just after Christmas and I have yet to get around to setting up a linux box to retrieve the data.

[Shink]

I acquired two DB9 grilles (one from my local scrappy, one from ebay) and pulled them apart.

Ha! The first thing I thought when I looked at it was "Aston Martin" and I couldn't figure out why. Sweet.

Thanks for the info. Have to say, I like a lot. Not sure if it's the look I'm going for but nonetheless, interesting.

[dtlwrc]

You have done great work there my friend! Your bumper looks great!

[punkuup5150]

how did you do the blinkers in the headlights i was thinking of this also for my c one front and just filling in the holes or putting more mesh there but would this be possible to do to a usdm set of head lights and do u have pictures of how u have everythign held in place id really like to find out how u did this

[Sh0gunkid8721]

looks alright i guess. would look better if it was cleaner. it seems like u have a million plastic things holding everything together. ur grille, ur headlights...doesnt even seem like ur hood is fitting properly.

[manphibian]

looks alright i guess. would look better if it was cleaner. it seems like u have a million plastic things holding everything together. ur grille, ur headlights...doesnt even seem like ur hood is fitting properly.

you're a jerk.

He said if you could read that it's not finished, the grille is temporary, and the headlights have JDM headlight covers.

[jason]

id be interested in those headlight covers... from looking, doesnt look like they are fitted too tightly to the low beams and possibly could wiggle a bit.

so far looking great!!! cant wait to see it finished

[Sh0gunkid8721]

looks alright i guess. would look better if it was cleaner. it seems like u have a million plastic things holding everything together. ur grille, ur headlights...doesnt even seem like ur hood is fitting properly.

you're a jerk.

He said if you could read that it's not finished, the grille is temporary, and the headlights have JDM headlight covers.

why am i a jerk for telling it as it is? its the truth isnt it? sorry i dont kiss peoples a*ses.


fine...edit: OOH MY GAWD THAT LOOKS AWESOME !!! happy? i tell it as it is...i wasnt rude about it. i wasnt mean. was totally civil about it.


p.s. there is no rule in these forums that state that u have to like everything that is done in this forum. as long as im not rude or an azz about things, im fully entitled to my opinions.

This post has been edited by Sh0gunkid8721: Feb 23, 2008 - 3:01 PM

[BloodyStupidDave...]

Thanks for all the comments.

how did you do the blinkers in the headlights i was thinking of this also for my c one front and just filling in the holes or putting more mesh there but would this be possible to do to a usdm set of head lights and do u have pictures of how u have everythign held in place id really like to find out how u did this

The JDM headlights have a separate parking lights beam. I simply used a dremel to carefully open up the hole to take a 3057 bulb and holder. 3057 bulbs are generally not used in UK models but are very common in JDM models. They are easy to acquire in most markets including the UK and the US.

If you take your time, you can open up the hole to take the new bulb holder and if you make the hole the right shape, the holder will clip in place and hold without the need for additional restraints.

3057 is a dual filament wedge bulb where the dim filament meets the UK and US requirements for a parking light and the bright filament meets the requirements for a turn signal (indicator). Alternatively, one could drill an additional hole in the high beam lamp (I believe the JDM non-clear high beam comes from the factory with the required hole), move the parking lamp function there and use the low beam parking lamp hole for the turn function. You might have problems finding a bulb that is bright enough withou scorching its holder, though.

I'm sorry I don't have any pictures at the moment. I will take some more pictures next time I remove the bumper.

looks alright i guess.

I'll take some more pictures when everything is finished. And I'll make sure the car is clean

id be interested in those headlight covers... from looking, doesnt look like they are fitted too tightly to the low beams and possibly could wiggle a bit.

The little black clips wedge between the headlight and the rubber and are then held in place with self-tapping screws. I never noticed that the headlights have places for the screws to screw into until I got the covers. Everything is very firm and secure but the lowbeam covers do seem a little small to me. It would have been better to have added another 5mm around the edge. But they certainly look the part.

I picked up the proper grille during the week and finally got a chance to fit it today. Looks much better now. Next: Sort out the side grilles and bumper/bonnet alignment.


This post has been edited by BloodyStupidDavey: Feb 23, 2008 - 3:29 PM

[Sh0gunkid8721]

Thanks for all the comments.

how did you do the blinkers in the headlights i was thinking of this also for my c one front and just filling in the holes or putting more mesh there but would this be possible to do to a usdm set of head lights and do u have pictures of how u have everythign held in place id really like to find out how u did this

The JDM headlights have a separate parking lights beam. I simply used a dremel to carefully open up the hole to take a 3057 bulb and holder. 3057 bulbs are generally not used in UK models but are very common in JDM models. They are easy to acquire in most markets including the UK and the US.

If you take your time, you can open up the hole to take the new bulb holder and if you make the hole the right shape, the holder will clip in place and hold without the need for additional restraints.

3057 is a dual filament wedge bulb where the dim filament meets the UK and US requirements for a parking light and the bright filament meets the requirements for a turn signal (indicator). Alternatively, one could drill an additional hole in the high beam lamp (I believe the JDM non-clear high beam comes from the factory with the required hole), move the parking lamp function there and use the low beam parking lamp hole for the turn function. You might have problems finding a bulb that is bright enough withou scorching its holder, though.

I'm sorry I don't have any pictures at the moment. I will take some more pictures next time I remove the bumper.

looks alright i guess.

I'll take some more pictures when everything is finished. And I'll make sure the car is clean

id be interested in those headlight covers... from looking, doesnt look like they are fitted too tightly to the low beams and possibly could wiggle a bit.

The little black clips wedge between the headlight and the rubber and are then held in place with self-tapping screws. I never noticed that the headlights have places for the screws to screw into until I got the covers. Everything is very firm and secure but the lowbeam covers do seem a little small to me. It would have been better to have added another 5mm around the edge. But they certainly look the part.

I picked up the proper grille during the week and finally got a chance to fit it today. Looks much better now. Next: Sort out the side grilles and bumper/bonnet alignment.

curious to know how ur going to make all that flush.


im out