Bumper progress

[VanishingImage]

Ive started on the AED front bumper. Getting the bad areas first priority then fitting it last since thats not going to be much work at all.

In these pics Im fixing a crack in the middle on the bottom. Basically cut a little bit out and re-fiberglassing a new piece. Then on the right side Im shaping the front "fang" since it was non exsistant. The other side still has its shape so Im using that to shape the bad side. Yes its body filler BUT its solely for shaping. Fiberglass will be put on top once the shape is finished. The fiberglass will hold and give it strength. Plus its not an area that flex which is what causes bondo/body filler to crack.

Click on pics to enlarge.......

http://img.photobucket.com/albums/v669/VanishingImage/th_STA70088.jpg (http://img.photobucket.com/albums/v669/VanishingImage/STA70088.jpg)
http://img.photobucket.com/albums/v669/VanishingImage/th_STA70087.jpg (http://img.photobucket.com/albums/v669/VanishingImage/STA70087.jpg)
http://img.photobucket.com/albums/v669/VanishingImage/th_STA70085.jpg (http://img.photobucket.com/albums/v669/VanishingImage/STA70085.jpg)
http://img.photobucket.com/albums/v669/VanishingImage/th_STA70083.jpg (http://img.photobucket.com/albums/v669/VanishingImage/STA70083.jpg)

[JoeyK]

Plastic filler is a product for filling/ shaping slight imperfections. You kinda did it backwards. Once you get it (bondo) over 1/4" thick you run a great risk of it cracking. You're better off repairing with the glass then use the filler (bondo) to fill in the minor imperfections.
Just remember that plastic filler is not for building structure, only for finishing off you're minor imperfections & you'll save yourself a lot of grief later down the road.

Hope it comes out ok, although I don't care for the manufacturer, the AED kit itself is very nice:)

[VanishingImage]

What could I use to shape then? Fiberglass has to have some sort of base to go on though doesn't it? Like stereo enclosures,fiberglass goes on after the cloth is layed out for the shape. So in this case what should I use?

[JoeyK]

Oh, are you using fiberglass fleece as the layering component for your resin? I suppose it can be used but is not the best material for an exterior application. Fleece is best for interior use where it's not going to take on much moisture or abuse.

The best & normal route for exterior fiberglassing is fiberglass cloth (which is woven fiberglass strands), or you can use chopped fiberglass mat. I guess you could use filler as sort of a reverse mold to lay onto to get your shape but you should spray it with a molding release agent so you can remove it from under the fiberglass after it cures. Using plastic filler to make a mold is an expensive route to take. Most guys will use wood scraps, pieces of thin, bendable metal,chicken wire, whatever to roughly build up to where you wanna lay (fiberglass) & go from there. I have, on occasion, used paint sticks as a frame & put several layers of tin foil over the frame structure, then sprayed with mold release (Pam cooking oil works too:) ) Then, after a thin layer of glass & resin is layed & cured I have something to keep building off of. Whenever I make anything I don't really care what the backside looks like (in most cases it doesn't really matter)so I use whatever I have laying around to help support the area I'm glassing. The best way, in your case, since this is a front bumper & it'll be taking on all sorts of abuse (from bugs, road debris, etc.) is to build your area up a bit past where you need with glass, then sand it down to your desired shape & lay a good heavy coat of resin on top & get your final shape. Then just use a skin coat of plastic filler to fill in your bubble holes. That way that bumper will be as tough as nails. Any point where plastic filler is used is a weak point, when it gets a good hit from something you got a crack. So by going pretty much completely fiberglass will give you a good solid bumper that you shouldn't have to worry about too much that is, unless you run into something large.

Hope that helps some. Those AED bumpers sit pretty low so you wanna make it as tough as you can.

:)

[VanishingImage]

I use the fiberglass cloth,I don't like the matting much. I just think it would be sort of hard to use that cloth to shape that corner up some.

Tiger hair or kitty hair wouldn't be ok to use would it?

I did all the body work on my Andy's AutoSport front bumper and nothing is cracking or chipping so thats why Im doing the same steps as I did with that bumper.

[JoeyK]

Tiger hair, Kitty hair, duraglass, they're all good for this type of application. You can go a bit deeper with it & it's a hell of alot tougher, just tougher to sand too!:lol:

[VanishingImage]

oh I know all about the sanding,whew!!

But thats the part I love,lol,keeps me busy

[VanishingImage]

Still working it everyday. Took all that bondo out and used some Fiberglass Hair stuff. Got the final fitting pretty much done so thats out of the way.

Now thats left is all the little small touch up jobs. I know we won't get them all but the guy that painted my body kit(the Andy's kit) is now painting full time so we have a little more access to him know than last time. He is still gonna offer the great work for this bumper. He charged me 350 for touch up work,primer,and paint for the whole body kit. So Im thinking around 150-175 for this bumper when we're done with the work.

Now its just time for saving some money for the paint:cool: I'll get more pics up ASAP!

[VanishingImage]

Got some more progress pics. Its getting VERY close to getting ready to go to the painter. He just has to do his touch up work to get it ready to his standards then primer and paint. I'll post up before pics then post the new pics of the same areas...........


Before any work was done........

http://img.photobucket.com/albums/v669/VanishingImage/myAED.jpg


And now the area after being fixed............

http://img.photobucket.com/albums/v669/VanishingImage/STA70103.jpg

some hood to bumper adjustment being done......

http://img.photobucket.com/albums/v669/VanishingImage/STA70096.jpg

[Big Joe]

looking good :D

[VanishingImage]

thank you kind sir:D

[VanishingImage]

Did some more fitting today,looks to be the last,but may have one more before we take it to the painter to have a look over for a quote.

Definately not going into the Auto Body profession,not enough patience for that! Passenger side of the bumper looks to be good,nice and flush,nothing flaring out. Driver's side is definately the part thats kicking us in the butt!!! The part where the bumper comes up by the headlight/fender area is flaring out. The part where the bumpers ends by the wheel isn't pulling up when tightening the bolts.

Im just glad it isnt like the Andys front bumper,that was almost a night mare. But this is a whole different ball game it seems. The problems aren't the same so its always a learning expirence.

[ga5speed02]

ryan it is comming along great. cant wait for more pics :)