Bumper Build
 

I thought I might share this bumper build here in case anybody is interested in doing their own bumper. On this particular bumper build, I applied my own style, but incorporated what I thought would improve my aerodynamic efficiency based on what I know about aerodynamics. I did not base this off of any wind tunnel or pieces of string taped to the car, just what I know about aerodynamics. I probably just got lucky on the design, because it certainly improves my fuel efficiency at higher speeds.

Here is a pic of my finished bumper:

http://i1242.photobucket.com/albums/...2473577095.jpg

All I did was mask off my original bumper with masking tape, and spray it with some mold release. I cut out a piece of metal shaped like my license plate and taped it in, and I taped in a piece of 0 gauge car audio wire to fill the gap between the hood and the bumper.

http://i1242.photobucket.com/albums/...1078468589.jpg

Next, I wrapped it up in fiberglass, let it dry, and popped it off of my taped up original bumper:

http://i1242.photobucket.com/albums/...2104036395.jpg

Then I used polyester body filler to smooth things out. Polyester body filler works great with polyester fiberglass resin.

http://i1242.photobucket.com/albums/...2104082654.jpg

Here you can see how the bumper curves up to fill the gap between the hood and the bumper if you look at the right lower corner of the head light. The factory bumper just goes straight across, level with the bottom of the head lights. I also made sure to make a very tight gap between the hood and bumper, since I do not want any air coming into the engine compartment.

http://i1242.photobucket.com/albums/...2540699125.jpg

I primered the project with good two part primer, and test fitted a bubble type license plate cover:

http://i1242.photobucket.com/albums/...3058357345.jpg

Took a mold of it in two halves...

http://i1242.photobucket.com/albums/...7027825962.jpg

Painted my project along with the rest of the car

http://i1242.photobucket.com/albums/...1524555169.jpg

And here it is ready for the road...

http://i1242.photobucket.com/albums/...1947639717.jpg

This is an electric conversion, so I did not need any air to enter the engine compartment at all. I have tested grill blocks on gasoline powered Metros, and I can assure you that you build something like this for a gasoline powered one, you will need air openings. Another word of caution, I built three inches into the bottom of this bumper for an air dam effect, and this does make it risky when I pull into a steep driveway.

It looks like you have experiance with it. But how long did it all tale to make? And how did you fastend it to the car

I molded the original mounting holes in up on the tips, so the top mounts like original. I have a career as a collision tech behind me, so I made the fit a little nicer than factory. I am a little weird about little details. The bottom mounts are all custom, since this transitions into a custom bottom underlay with its own aluminum frame.

AMAZING! Wow!!!!!

Can you elaborate more on the mold release spray and process? What brand?

I would love to come by and meet you /see your work sometime if you wouldn't mind.

Thanks. Here is the mold release that I like to use. I have a variety of different release agents around my shop, but like this stuff the most, especially on that masking tape.

http://i1242.photobucket.com/albums/...image.jpg1.jpg

Cool! somebody else in Sac Town! My shop is out in Rancho Cordova. I don't always have all the pretty cars here, so it is hard to see them all at the same time.

I like to build all kinds of custom cars, but I especially like saving Metro from the crusher. I really like the efficiency of these little cars, so I use them as a foundation for something a little nicer. This is what happens to Metros after they are dead and I tow them into my shop


http://i1242.photobucket.com/albums/...4037432535.jpg
http://i1242.photobucket.com/albums/...6765997575.jpg
http://i1242.photobucket.com/albums/...217_164620.jpg
http://i1242.photobucket.com/albums/...gejpg1-293.jpg

Only the 10th post, and I already love this thread!