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Custom Bumper: Gap Filling
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The Gap Filling process starts. |
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| Multiple Curves |
Pic 1
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Pic 1 There are three curves that have to be considered here.
A: The bumper curves both away from the camera the further you go to the right in this photo.
B: The bumper also has a slight curve downwards.
C: Finally, both of these curves if extended out have to meet against the curve formed by the newly inserted piece.
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| Using Template |
Pic 2
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Pic 3
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Pic 4
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Pic 2 Made a cardboard template to fit the curve of A.
Pic 3 Next, moved the template over and walked it down marking when it touched the insert and then 'connected the dots'.
Pic 4 Insert marked.
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Pic 5
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Pic 6
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Pic 7
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Pic 5 Made a cardboard template to fit the curve of B.
Pic 6 Next, moved the template over and walked it down marking when it touched the insert and then 'connected the dots'.
Pic 7 Insert marked using both the templates.
Note: This will allow the stock lines to continue and flow into the curved insert.
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| Materials |
| Note: I use heat on the PVC to form it. Heating PVC can release fumes that are hazardous. Do this only somewhere with plenty of ventilation. |
Pic 8
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Pic 9
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Pic 10
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Pic 8 I cut a PVC coupling in half, heated the section with a heat gun and pressed between a couple of 2x4's.
Pic 9 Let cool and removed. Should work fine.
Pic 10 Looking good. There is actually a slight curve in two directions on these pieces.
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| Full Bumper |
Pic 11
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Pic 12
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Pic 11 & Pic 12 Just a progress shot. The inserts are epoxied into the bumper. Let that set up overnight and I'll mold it tomorrow.
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| Attention to Detail |
| eTraxx (08:16 27 Feb 2007) : This is all very well but this project requires some things that are just outright necessary. One of these is the Duramix I am using for both an adhesive and as a 'liquid plastic'. I ordered some online .. and put in the wrong address (fat fingered a number). Bah ... |
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| Frank (13:36 27 Feb 2007) : I see a lot of labor going on here - that\'s for sure. But - I\'m also sure that it\'s definitely a labor of love - RIGHT? :-) |
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| Love |
| eTraxx (21:45 01 Mar 2007) : Hmm. Hadn't thought of it that way. Started out .. I'm looking at the bumper which is like . .a 5lb piece of plastic that people are paying upwards of $600 for. I'm like "this crap is worth it's weight in gold!" (ok ... or silver). ANYHOO .. figured .. surely I can beat that! Labor of Love? Now I suppose . . but started out as a Labor of Cheap! :) |
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