Bumper Build

[redneck]

.

Wow...

Nice work...


>

[AndrzejM]

Nice work, definitely!

[darcane]

So, the original fiberglass over the bumper is the actual part, not a mold you used to make the final bumper? And then the 2-part mold you later made is just to reproduce it if you damage it?

Did you have trouble making it fit since it would be larger than the original bumper?

[EVmetro]

Thanks fellas for the good words. Nice observation on the potentially larger size darcane. I actually went really thin below the head lights and along the upper edge along the fenders. Once the first shell was pulled off the taped up bumper, I put the rest of my glass on the inside so I could maintain the original dimensions and fit of the outside. The rest of the fit was in the blocking out of the filler and glass. The original shape and fit are there, but a lot of it came from milling. The milling makes for a nicer look and fit too.

[darcane]

OK, that makes sense. It looks well made and that would simplify the process a little. I haven't worked with fiberglass before, but I have some projects in mind and this method may work well.

Any pics of the inside, particularly of the mounts you made?

[Xist]

I am surprised that nobody has asked, would you ever consider selling these?

[EVmetro]

Originally Posted by darcane

OK, that makes sense. It looks well made and that would simplify the process a little. I haven't worked with fiberglass before, but I have some projects in mind and this method may work well.

Any pics of the inside, particularly of the mounts you made?

The tips where they bolt to the fenders are just factory style, which is just a hole for a bolt to go through. Since this is glass instead of plastic, I have a rubber grommet between the fender and the bumper, and then a bolt and nut. As for the bottom, this is where most of my support is. The pic below is my aluminum frame for my belly pan, and the front beam also supports my front bumper. I will show that next. This frame is mounted solidly to the chassis.



Here, you can see my support beams, linking the bumper to the belly pan frame.



Now the frame has been skinned, and the belly pan is flush with the custom bumper that is 3 inches lower than stock. When I put weight on wheels, the control arms settle just above the belly pan. The bumper mounting and the bottom underlay are all integrated as one system.



This set up sits pretty low, but really reduces aerodynamic drag. I do take this EV up to 100 mph, so I can really notice a difference at high speeds.

You can see the difference in how low it is compared to the metro in the foreground.

[user removed]

Kind of humorous, the Eldorado in the background .

regards
mech

[OG VX]

Ridiculous clean. More please!

[EVmetro]

Originally Posted by Xist

I am surprised that nobody has asked, would you ever consider selling these?

ya know... I really enjoy building custom cars and custom parts for them. While most custom car builders are into hot rods, my personal taste is in blending looks with fuel efficiency. I still go to Autorama car show every year to study the best hot rods, but good looking fuel efficient cars are still more impressive to me. I am interested in making a living in this department, but I have not yet figured out how to connect my skills and taste with making a living. My skills will always land me a journeyman spot in a bodyshop, but that is just production work. I have been developing a system of building EVs, and have even put a web site up for my EV business Welcome to Rusher Electric Vehicles | Rusher Electric Vehicles but I still have to do a lot of traditional auto repair to get by. I would love to be able to sell bumpers and body kits for different cars, and I think I have an eye for what looks good and is also fuel efficient. I just don't know which cars to build them for, and what would sell.