So I got this Windstar for my wife. It's a nice looking van, unfortunately, it was owned by a little old lady who had idiots at the local garage or some relative working on it. The RT side cornering light is out, and so dummy decided to cut the lower part of the bumper cover. A body man will know there are 2 separate pieces of plastic to the bumper cover (if not more) I'm referring to the lower section that's riveted to the outer cover. Someone cut that darn thing about 2' across the front to gain access I suppose, and now it's causing the RT side corner to sag. I doubt I'll be able to find another cover in the same color- so I'm considering repairing it. I already have to get in there and figure out why the windshield washer fluid container is leaking when about a gallon of fluid is in there.

Any advice on pulling the cover? I'm planning on using thin metal plates screwed to both sides, and maybe some epoxy to hold it together. Is there any other way that might be more effective aside of getting a new part?

I can provide pics some time tomorrow if needed. I have to go to work for a while, but should be home before dark I hope.

Thanks in advance. I think this van is going to end up being one of those vehicles that I always have to work on. [:(]

Post up some pics - I'm not a bodyman, but I'm a damage appraiser by profession.

^^ That is why I LOVE this site!!! We have people of every possible profession on here and 90% are willing to share their knowledge to their fellow focus fanatics!

[ffrocks][ffrocks]

i do a fair share of bodywork post up some pics i might help

im a certified body tech post some pics

as for the light it is odd that they would go in that direction i would probably have just poped the fender liner out and gain access.

as for the bumper i would have to see what it is that your talking about...

^^ That is why I LOVE this site!!! We have people of every possible profession on here and 90% are willing to share their knowledge to their fellow focus fanatics!

[ffrocks][ffrocks]

It is pretty cool!

OK, I'll get to it in the morning. I ended up working until 6, and then doing brakes until 9. Thanks for the help everyone, rep all around!

Pics!! Sorry it took so long, I took these this morning. I totally hate myself for getting this van because I didn't see the idiot damage done to it. It was a hurried thing anyway, and that always causes mistakes. Hopefully this won't be a $5500 mistake. If I'd seen that someone had folded the pinch weld on the Rt side using a floor jack- I'd never have bought it. Fortunately the engine and trans seem to be ok- after I hooked up all the carelessly forgotten vacuum lines.

Here's the damage: First off, the body style of the van. Mmmm foggy.
http://i29.photobucket.com/albums/c285/whynotthinkwhynot/Front.jpg

Left side under the bumper- notice it's screwed on the black side to the metal, and on the bumper side that black plastic is riveted in place which is why I think it might be difficult to get it without getting a whole bumper + paint if it's not right.

http://i29.photobucket.com/albums/c285/whynotthinkwhynot/LTunder.jpg

Rt side hanging bumper corner- if it was my DD, I wouldn't care much, but it's the wife's.
http://i29.photobucket.com/albums/c285/whynotthinkwhynot/RtSide.jpg

Here's the cut, it's possible it was also caused by a tow as the tow hook is on that side, and seems to have some rust/paint missing like a hook was put in there.

http://i29.photobucket.com/albums/c285/whynotthinkwhynot/RtUnder.jpg

You can see why I would think it would be possible to use thin gauge metal, epoxy, and some screws to mend it. I'd rather just have the right part put back in place- even if I have to drill the rivets and use plastic fasteners or machine screws with washer nuts glued to the other side. I'm just afraid I won't be able to find that part. Our local Ford Only yard only deals in late model, and would likely only sell me a complete bumper. It's doubtful that any other yard in town would have a late model van like this one because these guys buy everything going back 10 years.

heres a site that sells the bumper covers new and there in a few states hopefully they have a location close to you.pg 105
http://www.certifit.com/

Nowhere near Memphis, thanks though. I'm trying to avoid a new bumper cover + paint and all that. The paint is not great on this bumper, but it matches the body-LOL.

ok from what i can tell.. the cut in the bumper shouldn't effect anything... if it was bugging you then you might want to go get a new splash guard. as for how the bumper is hanging on the side it looks like a bolt is missing or something is not connected correctly.. i would look and see if their are any nuts or bolts missing if not i would say something broke and you might have to get a new bracket for it... is the bumper loose or just hanging down?

It could just be a loose spring clip every once in a while on my mom's mazda Mpv you you have to give the front bumper a slap to reset the spring clips back where they go. It is also a good idea to check for any loose or missing bolts. I have one other thing it could be. Check to make sure none of the bolts are pulled through the plastic of the bumper you may just have to add a washer to the bolt to pull the bumper back up. This happened to me in my truck when I had a minor incident. It pulled the bolts through tbe bumper some.

OK, guys, thanks- I'll check that. I've got to gain access to that area anyway to change the cornering light, and figure out what's up with the washer fluid reservoir. I also get to drill the freaking screws that hold that rotor in to take it off- I totally twisted up my T-40 the other night trying to get it off. I have no idea why Ford thinks that the lug nuts won't hold the rotor on like on every other FWD I know of.

Engines and other components I've got no problem with, and generally I don't have a problem with body work, this one being riveted together just threw me for a loop. Thanks again for the help, I really appreciate it.

Well, take a trip to your local pick and pull. I know at least here in Pittsburgh, many many Windstars gave their lives so that their owners could buy foci, civics, and cobalts. The local pick and pull got all of the c4c cars, and from what I understand has over 60 1999+ windstars. The odds of finding a bumper cover in the right color for cheap should be pretty good.