vistageek92

iTrader: (2)

I've long wanted to do this. Finally got down to getting the bumper pulled and my painter dated to come and paint it next week. When I painted the car 1 year ago for some reason the rear bumper never adheared properly. So has been flaking and coming off ever since. Driven my crazy because it made the car look bad.

I am also having my front lip and hood repainted: lip because of some road chipping and hood because a mechanic closed the hood on a socket and put a nice dent in it. So I am repairing that while I am at it. Trying to get it finalized for upcoming shows this summer.


So...first off. Bumper. Pulled, striped, almost fully sanded down and prep'd. Just need to shave the emblem strip.



A lot of problems with this arise because of rear bumper flex. So to avoid it cracking or popping out I am drilling feet holes for the fiberglass/bondo-glass to mold around and too. Also roughing up the area very well with 80grit. I'll have to be careful to mix the bondo hotter then usual, but very throughly as to not have unhardend bondo anywhere.

I also am bondoing/fiberglassing the backside of the area. To give the whole area support.

Now, obviously this isn't going to withstand a superman kick or a rear collision but if that were to happen we have larger issues then "oh, my bondo cracked"

The idea is to give it strength for vibrations and road movement while on the road. I am confident this will be plenty to suffice.



That's a start!

BlackenedBird

iTrader: (5)

Use a 2-part epoxy urethane filler not bondo & you won't hafta worry about flex popping it out & cracking the paint.

vistageek92

iTrader: (2)

I was considering this...I have used some in the past and it was absolutely horrible to work with...but maybe that as the fill and then just glass over with bondo...hmm

1ADan

iTrader: (4)

great idea, but i also agree to go with epoxy over bondo-hair type materials. look forward to seeing updates!

vistageek92

iTrader: (2)

Hey buddy! how's the ole 1A going? Still loving all my nice new weatherstripping and seals on my car.

The only thing I am worried about with the epoxy is I don't trust the bondo to adhear to it. I've worked with it before and there is almost no way to get a good enough sand finish on it for paint, meaning it would need a thin glaze of bondo..which I am worried wouldn't hold on... thoughts?

Jeffs82TA

iTrader: (1)

I disagree with using any filler, just buy the same urethane bumper and cut up pieces and melt them then pour into the cavity. I did this on a vette bumper.

1ADan

iTrader: (4)

that is the best idea if you can come by another bumper

also happy to hear you like your weatherstripping. still need to do mine sometime this year....

vistageek92

iTrader: (2)

Now that is an idea! I even have a trashed front bumper cover that I could use.

I hear you. Took me a good weekends worth of work to tear it all down and replace. Was worth it though!

Jeffs82TA

iTrader: (1)

You could also lay strips of urethane bumper in the cavity and use a heat iron to fuse it.

youtube urethane bumper repairs and there are many videos on how to repair them and those repairs can be used to fill the cavity and create and original stregth fill.

vistageek92

iTrader: (2)

I like it Jeff. Thanks for the idea. Sounds like I'll be melting bumper this evening.

Jeffs82TA

iTrader: (1)

Practice on a junk bumper first so you dont melt the hell out of your nice one. Those holes you drilled probably will help the urethane grip better to.

But watch the videos and you should be able to end up with a nice cover and after you have melted the stuff in just sand it smooth and it should never release even if hit.

vistageek92

iTrader: (2)

I'm thinking I'll melt it off the bumper and pour it. I don't like the idea of melting the strips on the bumper.

Jeffs82TA

iTrader: (1)

Is what I did when I filled mine was do section fills and had a damp towel handy to cool down excessive hot spots fast. A heat gun with small heat iron attachment works well for fusing too. There are a couple ways you can do it, just take your time, by section filling I mean pour a little in each spot at a time and build it up. If you go the route of liquifying urethane when pouring just make sure it isn't so hot that it burns right through.

If you have a front bumper IIRC the nose emblem fits in a recessed area just remove it and practice filling that. Grind into the urethane so there is no paint/primer.

After it is filled just sand smooth and have a trouble free bumper.

vistageek92

iTrader: (2)

I'll keep ya'll updated on how it goes tonight.

mh82camaro

i think it will look nice.....keep updates

Jeffs82TA

iTrader: (1)

Oh and of course wear some thick gloves, hot urethane on skin ain't a pleasant feeling.

bluegrassz

iTrader: (3)

I hope the fill process works. I have a spot my side skirt that needs repaired. A plastic welder would work for my issue. Harbor Freight usually has a good deal on them.

Jeffs82TA

iTrader: (1)

One of these drill attachments from pepboys (rust remover) should clean up the fill area fast just watch it cause it will cut into the
urethane fast.

I think that area is what about 1/8th inch thick? That should absorb the liquified urethane without melting through. One of those wide metal putty knives should work well in countouring the urethane as it is hardening.

Spike-Z

iTrader: (4)

Body shop did it for me, no idea what was used. Its been holding great for the past years.

vistageek92

iTrader: (2)

That picture is the whole reason I have wanted to do this. Your build on LS1 tech is just beautiful. If I ever get the chance to do what you did with your car, I will be a lucky man! Great work!

vistageek92

iTrader: (2)

UPDATE!


Bad news first. Our plan on melting in the area with the scrap bumper was a complete failure. I spent two hours trying to get it to melt properly. The problem is, as soon as it gets hot enough to melt, it also combusts!

So I am going with my original plan. Love the idea, and many thanks to Jeff for the idea, I think it would work beautifully if I press melted them in, but I don't feel comfortable doing that, with the chance of harming my own bumper.

First coat of bondo hair going in.




Quick sand:




Second coat of Bondo-Hair going in.





That should be all the fiberglass I need. That'll get sanded down either late tonight or tomorrow, then Bondo will be glazed over that. Should turnout baby butt smooth. I'll get a pick of the backside too so ya'll can see how the foot holes I drilled, worked out.

86_irocz-28

Just found this thread ive been doin the same with my rear bumber, fuel door, and my 92 side skirts heres a pic of them check my build thread in my sig for more pics

Close up(the gap is due to it wasnt bolted up yet)

Jeffs82TA

iTrader: (1)

Well how hot did you get it? I did it and it worked fine or did you try nuking it at a million degrees lol

vistageek92

iTrader: (2)

Yeah, Ive been following your thread, very interested to see how it turns out.

nope, controlled burner. Like I said, spent 2 hours at different heats doing a slow gradual heat. But I mean as soon as it started melting it would ignite.

Jeffs82TA

iTrader: (1)

That is weird, mine worked fine. Make us a video though!

vistageek92

iTrader: (2)

If I feel like getting all the stuff out again, I will. Busy day so might not be able too.

BlackenedBird

iTrader: (5)

I hope that ground fx piece isn't finished yet, because the outline of the filled section is still very visible.

browncamaroz28

iTrader: (1)

when i had my wrx i got a free bumper cover that some idiot cut a 3 inch intake hole in. the 2-part urethane worked perfect and was able to be sanded down so that very minimal filler was needed. Just my exprience, but bondo fiber will probably work also.

86_irocz-28

Yea im still working on it got alot of other body work that ive been doing lately ill post finished product when done

el_muerte

I have some of the flexible 2-part bumper stuff holding a crack together on my nose... I found it clogs up sandpaper quicker than Bondo, but is just as sandable and easy to shape.

vistageek92

iTrader: (2)

Yup yup. I used it to fix two fist sized holes in my front bumper. But it absolutely sucked getting to sand down properly. At least the stuff I used did...


Some more progress pics coming soon. Finished with the fiberglass. Body filler going on now.

project89

iTrader: (1)

hows it comming along im about to do this on my rear bumper cover

Mirror Image

iTrader: (2)

What type of plastic is the bumper im right they are PUR if so it is not good to melt the plastic it will break down the compound and can fail you need a patch of the same type of meterial and weld it in

vistageek92

iTrader: (2)

Ill try and update tomorrow. its finishe, just been to busy with my rear swap. ill get pics tomorrow!

project89

iTrader: (1)

i started mine tonight ill post up some pics in a bit

im doing mine with an epoxy and then a light coat of flexible bondo over that

i drilled a bunch of 1/4 holes down the strip
then i duckt taped a peice of alimunum flat stock on the backside with an 1/8th inch gap between the flat bar and the bumper cover

then i poured the epoxy in leaving it slightly below the surface so i could finish it off with the flexable bondo


im waiting for the epoxy to dry now when it dries ill grab some pics

vistageek92

iTrader: (2)

That sounds good. I was very happy on how my fiberglass/bondo worked out. Not complaining at all. Has plenty of flex and support.

project89

iTrader: (1)

i do not like the bondo im using , its made for like 2002 and up cars with plastic and rubber panels.

the problem is its very hard to sand and it goes on way to thick to work real nice.

the bumper cover only needs a very final tlight thin coat so im going to pick up some of the normal grey or red body filler and see what happenes .i hate to use that stuff since its not flexable but this other stuff is just way to hard to shape and sand

project89

iTrader: (1)

this is as far as i got with smoothing my rear bumper cover.

need to pick up some different filler that will work on the plastic cover as the stuff i got for it is way to hard to sand and shape, and it is to thick to go on as thin is a need it to to finish

vistageek92

iTrader: (2)

Looks really good man. Def needs some more. I can still see the outline of it. I havent had a chance to get pics of mine yet. I have been nose to the grind stone getting the car ready for Saturday. Still have a Hood to finish prepping...

project89

iTrader: (1)

yeah it needs one more really thin coat.
i have more of the stuff ive been using but its very thick and it dosent sand down very easy so i decided to wait till i get some other filler to try out instead of fighting with the stuff i have

vistageek92

iTrader: (2)

You not wanting to use Bondo Gold?

project89

iTrader: (1)

thats what i have now its green, its just so dam hard to sand compared to the red or grey filler.i may try to do the final coat with it i just wish there was a way to thin it out a lil bit before i applied it

86_irocz-28

mines almost done ill get pics when im finished

vistageek92

iTrader: (2)

The green stuff has the fiberglass in it. Get the actual Bondo Gold Body Filler. It'll mix almost pink/tan. That's what you need to be using as the last filler.

Sweet man!!

86_irocz-28

bumbers finished!!! i have pics posted in my thread, links in my sig

vistageek92

iTrader: (2)

Looks great man!

vistageek92

iTrader: (2)

Well guys, this was the ultimate outcome. Turned out great IMO.

obeymybird

iTrader: (4)

nice................

vistageek92

iTrader: (2)

Thanks! I like it myself!

90_383

looks good , nice work