Lets talk Bumperettes if your interested.

[azygoustoyou]

I know I brought this up before. I've decided to make a mold for bumperettes on the car. I decided to make them bigger than the ones I have which means wider. They would just cover the bumper hole.
I decided to make them more rounded than others. I remember someone saying they wished they weren't so square.
In the pictures you will see they are close in design as mine are.


Here's what they would look like on the car. The line on the side represents about how much would need to be cut from the opposite side to make them square. All four bumperettes would have basically the same shape. Except the backs would be a little bigger at the bottom so they can reach the fender.



These wouldn't be just a bolt on ordeal. Everyone's cars aren't shaped exactly the same. I can get the bumper close but you probably would have to do some shaping. Also in order for you to shape them, the connecting part in the bumper would probably have to be installed by you. I'll try to figure something out on that later.They will be constructed of fiber glass. They can be done with carbon fiber.

What are your thoughts about shape and design? About you having to adjust the curve to fit your car? And of course Price. All opinions welcome. It took me no time to make this foam mold.

[azygoustoyou]

Update;
I tried to cover it with bondo and it didn't work too well.
Back to the drawing board. Looks like I'll have to shape it out of pressed wood like my other ones.
Doing these things over and over just burns me out

[manoa matt]

I would consider finding some peel and stick weatherstripping, black closed cell foam, or neoprene that can be installed on the edges that meet up with the body. Don't apply it, but include strips of it with the bumpers. The gasket will compress and take up any gaps that would exist from one car to another, therefore the owner would not have to trim the edges. If you trim the edges, you need to apply another gel coat over the cut edges to prevent delamination.

The owner would have the option to install it with or without the gasket and deal with the potential gaps.

Yep, can't apply bondo or fiberglass over polystyrene....unless you are trying to make napalm or a gooey mess.

I'm guessing there is a pate on the inside that sandwiches the body sheet metal?

They look very well made.

[azygoustoyou]

I'm using a large washer, a lock washer, and the nut. I'll loctite the nut.
Good idea with the trim strip.
I just found out after polishing my first bumper that the resin isn't UV protected. Now I'll have to clear coat them. Just another step. I have three of the four done. Almost done with the fourth.

If I make the molds, I'll use the UV gel coat and do them right. LOL

[manoa matt]

How about instead of all that "hardware" you just use a nylock nut.

[v6spider]

I am considering TIG-ing some out of aluminum plate and polishing them... also considering making them to fit inside the rectangular bumper mount hole... Thoughts?

Rob

[azygoustoyou]

Guess what? I went out to the garage to get a beer. I checked the bumperette and it was fine.
The problem earlier wasn't it melted. It was I didn't think it was going to get hard enough.
So I put a second coat of body filler on it. Tomorrow I'll sand it down some to see how it turns out. The reason
it looks weird is because it is extended toward the back so I can shape it for all four corners.

[azygoustoyou]

I am considering TIG-ing some out of aluminum plate and polishing them... also considering making them to fit inside the rectangular bumper mount hole... Thoughts?

Rob

I was thinking of making these to do the same since most people would want them to go over the bumper holes.
On my car, they have to stay where their at since I used the bumper holes for reverse lights in the back and made hold to secure the ones on the front.

[v6spider]

I was thinking of making these to do the same since most people would want them to go over the bumper holes.
On my car, they have to stay where their at since I used the bumper holes for reverse lights in the back and made hold to secure the ones on the front.

This is especially true for the round hole bumper mounts.... been thinking about this more and not only having them inset. But follow the curve and only protrude about half an inch or so from the aware mount hole. Btw I don't know if you've seenmy post but my reverse lights will be mounted in the center of the inner taillights..

Rob

[meangreenspider]

I have considered attempting to make a set for the rear myself but have not done anything yet. I like the process you're using and think it should work well. the set for your car look great. Have you considered covering them with fiberglass gel and matting? In my experience the fiberglass gel has been a little stronger than the average body filler and sands easily also. Are you considering making these to sell? If so, I would love to buy a set for the rear of my car. I had the holes in the front welded over before my car was painted so only need rear bumperettes.

[azygoustoyou]

I was wondering why there was a dark circle in the center when your brake lights were on Rob.
Meangreenspider,
Working with the resin is what I ended up doing on the last mold. You could always put the fronts on like I did on my car.
I drilled two holes and mounted them.

[v6spider]

Brady,
funny the photo you are mentioning was an effect of the Flash reflecting on the lens. Apparently the center of the light is non-reflective...

I have posted a couple shots of the lens I constructed showing the front and backside not mounted in the car...
http://www.fiatspider.com/f08/viewtopic.php?f=7&t=13711

Cheers!

Rob

[grittracing]

have you worked the back out yet or are you still on the front? I maybe interested in a set for the rear i dont really car for how my rear set up looks . So far i like what i see. Pm with a price if your ready.

[geno58]

If you are going to use polystyrene foam with a polyester resin, coat the foam with latex paint and let it dry real well.

[geno58]

Another thought, once the molds are made, use a pourable urethane rubber, and instead of leaving mounting studs sticking out of the back, cast some incerts into the body. it would make final fitting easier. your whole project sounds like a good one. The key is to make them with as little hand labor as possible, to keep the price below the other suppliers out there. All so white Gel-coat is about as UV resistant as your going to get.
30 years in the Fantastic Plastic Buisness, AAHH the smell of Styrene!