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Old 08-05-2012, 02:36 PM   #65
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Location: Buffalo, NY
What I Drive: 03 SVT (RS conversion)

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well, I'm starting to think I need to try to find someone with genuine RS front fenders and try to borrow them for molding purposes. This is turning into a clusterf*(%

Mounted the bumper......NEWS FLASH! The RS fender's nose is much more "flat" than the standard fender(which has a bit of a curve to it)

pic from below:

so I traced the line of the bumper, and went at the fender with the grinder to cut the curve out of it. Then I welded a flat patch behind it so I could smooth it all out with fiberglass and body filler.

definitely not excited about how it's coming out right now, and would MUCH MUCH rather re-mold an OEM genuine (not dented to piss) RS fender set. Fantastic, I'll have to do this all over again on the passenger side. :-/
My majorly huge hand-made Focus RS replica build:
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