How to make custom bumperettes

[azygoustoyou]

I made the first mold for the back bumper. I was worried about separating the back when I first started this after seeing how hard it was for me to release the front bumpers. But not with the PVA. You just have to be careful not to stab yourself with the screwdriver. Don't ask. I did have to remove the wax I put on the bumper though. The PVA didn't want to stick. So I used an some pre-paint to clean it off. There was no problem after that. You can see the PVA on the bumper. It just peels off.

[azygoustoyou]

I must be getting faster at this. I got both rear molds done today.

[azygoustoyou]

We'll I have to say. If you have all your patterns cut and everything lined up with a plan on how your going to lay each piece. You can do this pretty quick. Plus after making the molds. You get an idea on how much resin to mix. I was able to do the back bumperettes within a few hours not counting spraying the PVA on. It takes up to an hour for that to dry each one. I don't know how long you have after you spray that stuff. So I did each one right before making them.

[bwilson27]

Practice makes perfect. Thanks for the updates!

[azygoustoyou]

I have one of the back bumpers shaped. It was interesting trying to find the lines. I have to fix a dent on the other side before I can shape the other. Here are pic's of the way it looks. I'm looking for your opinions. Do they look to big,etc..? I'm putting my reverse lights in the bumper holes. I cut a small piece off the end of the valance fold to put the bumper more to the center. I didn't want to cut the outside of the bumper to go over the fold like I did on the inside. I did square out the bumper also. The inside is thinner than the outside.

[azygoustoyou]

Finishing up with installation. There are different ways to go about this. I chose to do studs within the bumpers. I used stainless bolts welded to a stainless base. (Thanks to my buddy Bob) They were bead blasted to help grip the resin also.
You have to rough up the inside of the bumpers so the resin can grip. Mark the inside of the bumper where you want the bracket to rest. Try to get the bracket centered and look at the bumpers from the side to make sure they are about 90 degrees from the edge so they will be easy to put on. Cut a lot of small pieces of mat to put into the resin for strength.
I took some tape and taped up the area on the car where I wanted the bumpers to go. I outlined each one with a marker. I then cut out two templates of soda cardboard box. You need something flexible. I cut two holes for the bolts to go through on each one. I made sure there was some overlap on each side of the bumper.
After the resin dries. I will place the cardboard on top of the bumpers placing the bolts in the hole openings. Trace around the bumpers and cut it out. Now you have a template to take to the car and place on top of the outline to drill your holes.

[azygoustoyou]

WOW It feels great to see these on the car. I left them gray so you can see them.

[SLOSpider]

I cant tell my the finished pics but are they pointed straight ? I was wondering if you made the outside edge an little wider for this. Looking great and Im sorry that the Fiat is taking the money that you have to get Sierra Mist instead of Mountain Dew

[azygoustoyou]

I'll have to take a pic of it downward to see how they are sitting. I did make the outside walls wider so they would sit more square. I know they aren't perfectly square. I can see that myself. I'll show the pic tomorrow. Even though I think they look great.

[kmead]

Looks great, glad you got the PVA to make the molds you labored over work the way you wanted without having to create new ones.

It is really nice to see someone really make their car completely their own, with their own hands. Great work, looking forward to seeing it all come together.

Karl

[azygoustoyou]

Thanks a lot Karl,
It sure does feel good to get to the next step.
Here's a pic of a downward view. They are bad. I like them. They aren't completely square either. I don't want to take anymore off. Then they'll be too thin.

[kmac33]

Brady,
I can't wait to see the finished car. You are doing some amazing work
I think your Fiat restoration "crack" habit may be as bad as mine

[kmac33]

Brady,
I can't wait to see the finished car. You are doing some amazing work
I think your Fiat restoration "crack" habit may be as bad as mine

[azygoustoyou]

My wife says she agrees with you.
By the way that's her smiling.