how to chop and then re-glass a fiberglass front bumper

this is a lil write-up about chopping a cheyanna (sp) bumper for the mk4 made out of fiberglass then putting the 9 pieces back together again and what kind of gaps you create when channeling the bumper 3 inches to match the bottom of the body so you do not have to run side skirts.
the left side being fitted back together ( i use duck tape so that you can get the general shape and then fiberglass from the inside out)

this is the gap made buy shorting the height of the bumper on the side

coming together in the front

a filler piece for the bottom center gap

inner left shot

close up of left

close up of right

right side at angle

gap on right side by the wheel opening

size of section removed from right and left sides

all taped and ready to be pulled off for glass work

inner left side ruffed up for new glass ( i used a grinder with a cut-off wheel to ruff the surface and expose some inner glass

inner center section

another inner side shot

tape is used to hold the shape of the center section whill it drys

progress of glass on inner sides

next shots are after inner repairs are done still not finished with end caps by the wheel well. (pre-grinding so very ruff and not perfectly alined)

these are after a very ruff grind and basic shaping ( it will be shaped and iced some more )

center repair section

close up of wheel well repair

these are final shots before resin-jelly is applied (like bondo for fiberglass)

here is the bumper after resin-jelly has been sanded and a guide coat of primer is applied (still needs fanal bondo to fill small holes and scratchs and shaping)
YOU WILL SEE SOME BLACK SPRAYPAINT OVER SPRAY IN SOME SHOTS THAT IS WHY SOME PARTS DON'T LOOK RIGHT, OKIES

THE FINISHED PRODUCT

i hope that this was entertaining and informative.

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Last edited by fxgolf on Sun Mar 22, 2009 9:57 pm; edited 4 times in total

looks good, any reason its yellow?

when i as helping out my neighbor pathcing up his car with it, didnt look like that Oo was a lot cleaer

Nice work so far man. Be sure to do some type of reinforcement on the outside or it might crack at the seams... I learned the hard way.

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it is only half way done. as far as the yellow ness i don't know. maybe bondos color choice. or maybe cause i mix it a lil hot so it bonds in fast.

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definitely the mix, and probably cause it's thicker as well.

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looks good and stable! some cloth or fiber supports would definitely ++ it's structural integrity... can't wait to see it in person!!

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Prob just need some CF vinyl to finish it off ;)

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1992 MkII Jetta GL 8V

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lol

fiber glass and bare feet ftw!!!!

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EuroHOH merchandise!!!
http://www.cafepress.com/DubLyf

"never trust a fart" -Jack Nicholas, "the bucket list"-

hells ya don't want to get the kicks all sticky. but that shot was after a clean-up. so no real danger to the piggies. PDT_Aliboronz_20

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updated hopefully will be able to finish it and paint it soon. but there is a shadow lurking. PDT_Aliboronz_20

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madness in a can of spam.

Can you make me one out of an old boat and some duct tape? MacGuyver could.

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-A. Dub
1992 MkII Jetta GL 8V

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hell ya i could, seriously i could. PDT_Aliboronz_01

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madness in a can of spam.

Where's the final!!! Still waiting ;)

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-A. Dub
1992 MkII Jetta GL 8V

(I like playing with forums)
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neko's got it for now...

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The ultimate in automatic rice cooking!
- Allows you to cook rice perfectly every time.
- "When you think of rice cooker, think of Zojirushi."

I know, but I still need the eye candy!

_________________
-A. Dub
1992 MkII Jetta GL 8V

(I like playing with forums)
Vortex Posts