My Homemade Aero Bumper - Fuelly Forums

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Old 09-11-2009, 08:11 AM   #1
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My Homemade Aero Bumper

I had a spare front bumper for Thrifty McGassaver (my VX) and this is what I've done with it so far:




Done with the help of a buddy of mine that I work with in the summer. Took about 20 hours to get to this stage. Next up is a lower lip air dam.
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controversy is an idea thought up by weak people who are too afraid to hear the truth.
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Old 09-11-2009, 08:16 AM   #2
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That's really fantastic! What techniques did you use?
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Old 09-11-2009, 08:52 AM   #3
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I used Great Stuff expanding foam to lay down a backing for the fiberglass jelly to cling to. Then the final step was to shape and smooth the jelly and then skim coat with Bondo. And then paint.

Next bumper I'm making will use plastic welding though. It will be faster than the methods I used on this bumper.
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controversy is an idea thought up by weak people who are too afraid to hear the truth.
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Old 09-11-2009, 10:23 AM   #4
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Holy crap, that looks great. I wish I was capable of that sort of work.
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Old 09-11-2009, 10:35 AM   #5
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I like the asymmetry.
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Old 09-11-2009, 10:55 AM   #6
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Next bumper I'm making will use plastic welding though. It will be faster than the methods I used on this bumper.
You could also consider some PVC cement. I have used it several times to patch together motorcycle fairings. It is strong as hell and you can sand it as well.
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Old 09-15-2009, 09:35 AM   #7
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Just a little teaser:

I started making the lip last night and will have it done tonight after I stop off at Home Depot. Expect pics late tonight or tomorrow morning.

Home Depot is my favorite auto parts store!
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Old 09-15-2009, 05:28 PM   #8
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Very very nice work. It gives me ideas for my Yaris hatchback front.
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Old 09-16-2009, 03:10 AM   #9
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Wouldn't you have warranty issues with that?
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co de pen den cy
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Function: noun
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Old 09-16-2009, 03:40 AM   #10
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His warranty ended almost 10 years ago.
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