New front bumper

General Composites Discussions Showcase
#1

The problem with the front bumper on the integrale is that it slopes back at the bottom making it hard to fit a front mounted intercooler which you really need when you are tuning for more power.
I made a new mould which takes into account the vital parts of the original bumper and combines them with some more space.

The original:

First I made a new OE style bumper from FG, then I hacked it around, added the bits I needed with stuff I had kicking around, the centre was some laminate flooring, braced with some skirting board to keep it straight! I then added other bits and backed it all up with what we call ‘filler foam’ (expanding foam from a pressurised can) I smoothed it all down with car body filler, again and again and again until it was just right, then coated it with 2k paint and left it plenty of time to harden before waxing it and taking a mould from it.

Here below is the result, the first part came out just fine. I coloured the gelcoat yellow so if it picks up stone chips when painted they won’t be so visible, we had to mix some white with an off-the-shelf yellow pigment to get it just so. One happy owner:

Just gotta source a good intercooler now to fill it.

#2

Nice work! Gonna look great with an IC in there.

#3

Thanks!

Pic of the finished plug:

And a couple more of the detail:

As you can see all the original bits and pieces fit (apart from the centre grille!) And the lines on the bumper follow down from the radiator grille and the bonnet.

The ‘purists’ won’t like it and I won’t sell many at all, but it was an interesting project for me and I learned some more. I gotta admit I’m quite enjoying learning all this new stuff. :slight_smile:

#4

im very impressed!!! good job

#5

it’s a mean machine! nice work, well done! :slight_smile:

#6

Just a bit of an update, I found a cooler which fits and complements the lines of the car, I also made a CF bonnet:

Haven’t re-routed the oil cooler yet or fixed the side mountings on the bumper hence the cooler dangling underneath and the props. :o

#7

Thats a cool looking car! The fenders flares remind me of the 06 WRX.

#8

Good job with the redesign of the bumper. Looks well done.
Now just paint the hood and it will all go together well!

#9

Thanks for the complements guys.

Hey whassup with the hornet look??!

C’mon TET, load up and kick some Spammer butt. :smiley:

#10

Haven’t seen any spam in this thread. But if you see any, there’s a “report” button to click on!

#11

looks good here