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Old 09-27-2012, 10:09 PM   #1
Flow~cus
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Need advice on repairing bumpers... What do I need. Pics included.

I am looking to do some repairs on my front and rear bumpers. What materials will I need/ should I get? This will be my first try at body work so any tips/tricks will be appreciated. I cant afford new bumpers right now (although I would trade and throw cash for a euro rear bumper) so Im going to try to fix them on my own.

Front bumper:
First...I rear-ended a lady a few years back resulting in a nice gash right in the middle of the bumper with a small cut underneath it. This is my biggest peev with my car. My whole front bumper looks like crap but this makes it worse. Also I want to get rid of the front licence plate bolt holes. Heres the pics:



Second...A bag of trash fell out of a truck about 8 months ago and found its way right into my front bumper. It cracked the bumper all the way through right under my drivers side fog light. This seems like the more difficult repair to me. Here are the pics:



Rear Bumper:
My father backed into me with his truck and the trailer hitch put a nice little ding in my rear bumper. Its right on the crease of the SVT bumper.




My biggest thing is what materials to use? I can get some body filler but i wasnt sure how that would work out with the bumper material. I know I will need to sand it, do the work, sand it again, and eventually paint it. Just need to know what will work to fix the marks.

Thanks!


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Old 09-27-2012, 11:23 PM   #2
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I think you are going to be best to repaint the whole thing.


I recommend:

Fiberglass + Resin. Use this to patch up the major holes and get them as level as possible. Too much bondo will just break out, so you want as little bondo as possible.

Bondo, then sand sand sand sand sand.

Start with 400grit (280 if you really need too) then work to 800. Prime and sand again. Use light applications of bondo to cover over any trouble spots that appear. Repeat process until smooth.

Give a final sanding of 800 grit on the primer (it shouldnt sand through), then paint.

Thats what I did at least. Worked fine for me.
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Old 09-28-2012, 02:22 PM   #3
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FYI: There are at least two vids on youtube. search for bumper repair (or something like that).
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Old 09-28-2012, 02:37 PM   #4
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I would stay away from fiberglass products, because they have a different expansion rate than the urethane of the bumper, and the areas you repair will show back up in about a year or so after going through a number of expansion cycles due to solar exposure, weather, etc.

What I reccomend is this:

start out by getting yourself a cheap Harbor Freight plastic welder. It's $10 or so.

take some heavy grit sandpaper to the areas around your damage, about 2" away from all spots you plan to repair

use the plastic welder to "weld" your cracks closed

now, at this point I personally like to go a little overboard to make sure the repair is permanent and essentially stronger than the rest of the bumper. I'll get into what I'd do later but you can just use some 2-part urethane or plastic epoxy on the newly welded cracks and surrounding area, then let dry, sand with 220, 320, 400, 600 until flat and smooth....then prime and paint.

if it were me, I'd go nuts.... I'd drill a couple 1/8" holes either side of the crack, then use a dremel or file to "connect the dots"....meaning create valleys in the plastic from hole to hole accross the crack. Then I'd use a counter-sink bit on either side of the bumper in the 1/8" holes, and cover the back side with masking tape, and apply the same 2-part epoxy I mentioned all over the area. what this will do, is form an epoxy "weave" that will not be able to break away from the bumper due to the holes having counter-sinks on both sides, and the holes being connected from grinding valleys between them. (I hope that description makes sense)

^ that's how I repaired a busted corner on my RS bumper, and a busted corner on my RS wing in my build thread. I have a BADLY damaged facelift euro front bumper I plan to repair with this process too, so when I get to that I'll make a How-To thread.
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Old 09-28-2012, 02:46 PM   #5
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I bought a urethane (flexible bumper repair kit) something or other last time I fixed mine.
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Old 09-28-2012, 02:51 PM   #6
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http://www.youtube.com/watch?v=mTY_OpX3dvQ
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Old 10-01-2012, 10:15 PM   #7
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A flexable bumper repair kit is what i used and applied it to both sides of the bumper cover to act as a better reinforcement. It is usually a 2-part expoxy resin that you mix together and then apply to a good clean sanded surface.

Hope this helps !
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Old 10-01-2012, 10:31 PM   #8
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Just ordered a bunch of stuff that should get the job done. Plastic Welder to piece it together, Sem-weld to hold it together, and Poly-Flex to finish it off. Got some ideas for the bumper in addition to fixing the damage.

Everything should be here this week (along with some other goodies ) so the ole Flow~cus should look a little different in a couple weeks time.
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Old 10-07-2012, 07:40 PM   #9
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I have the same issue on the car I just bought by each fog light.
I was thinking of just epoxying the inside of the bumper, and having it kind of hold from the back.. so the crack kind of flushes back together.
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