Bumperettes

I've been messing around with the bumperettes on my 1985 coupe, looking for a way to slim them down, like Euro ones. Why not just buy Euro ones, you ask? Well, because . . . I don't know. I like to make unique custom pieces, even though they take too long, are too complicated, and end up costing a fortune.

Bandsaw sectioned 4 inches out of center of each bumperette.



Looking better.



Traced shape onto 1/8th inch of aluminum (test piece--actual part will be in stainless)



This is how the spacer will look. Bumperette halves will be glued tight.



Uh oh! In making this design in my head, I neglected to account for the curvature of the bumper. Outboard piece of bumperette does not align with inboard. Time for a course correction--the spacer will be polished, and will have a reveal on the outside.

Also, the center of the bumper is slightly canted vertically, different from the outboard ends. Required a lot of grinding and filing on the internals of the bumperette to get to this point.



Spacer will need to be lengthened somewhat in this area. Fortunately, with the bumpers tucked in, this part of the bumperette will be basically hidden.



Revised bumperette now mocked in place on the bumper. Still deciding whether this will all work and whether I'll be happy with the final product.



Inside view.



Outside view, showing the extent of the reveal which will be polished. I think it will work, but welcome any opinions.



My next door neighbor teaches welding, plasma cutting, and CAD at a local community college. Next quarter I'll be taking his CAD class. Should come in handy with this project.

[Flojo]

Ok, why not indeed... BUT... once you get hit, the metal spacer will bend and ram its way into your bumper...

edit.. delet em completely. use aftermarket lights for the plate. clean(er).

[sugarwood]

^^ LOL, funny how we obsess over the aesthetics and forget their reason for existing

Originally Posted by sugarwood

^^ LOL, funny how we obsess over the aesthetics and forget their reason for existing

Indeed!

I'm pretty much resigned to the fact that the things I am doing--including tucking in the bumpers--will make the car more susceptible to damage from a rear hit. It's a worry with fiberglass bumpers and backdated cars too. That said, I'm not sure the bumpers on the jacked-up four wheel drives that I share the road with would match up well anyway!

[darrin]

Madcorgi -- would almost seem that going bumperette-less might give you better protection against a parking tap than your chopped bumperettes, as it seems the metal plate you've made would focus/amplify an impact into the bumper, rather than dissapating/absorbing it as would occur with a traditional rubber bumperette.

[proporsche]

as Sugarwood said..+1
i might be the only one in Europe who likes the US version of Bumper Guards..yes they guard the 911 very well.
Back in La i got hit by a stone person with Prius and the Prius was totaled the whole front...mine..
i just realigned the bumper shocks and the bumper..nothing got broken ...so i love my US bumper guards on my Euro model 911...;-)

Still messing around with things. Drilled into the bumper shocks and hit hydraulic oil, then, a bit deeper, and into the inside tube, gas of some sort came whistling out--for quite awhile.



Tapped the bumper shocks in about an inch, then drilled and tapped a set screw.



Test fit the the bumper. Still wrestling with how to fill the gap.







Then, just as I was about to call it a day, the mailman brought a present--the Cayman S exhaust tip I bought from Pelicaner JH282. Thanks, JH--part was exactly as represented. I stuck it roughly in place under the bumper to see how it will look. Nice!

Tomorrow will be welding day.

[acme911]

Hey Madcorgi,

Regarding what to do with gap. If you plan to keep the accordions then cut down the extensions. The front is the opposite. Need to cut down bumper.

Andy

Originally Posted by acme911

Hey Madcorgi,

Regarding what to do with gap. If you plan to keep the accordions then cut down the extensions. The front is the opposite. Need to cut down bumper.

Andy

Thanks, Andy. I'm actually toying with the idea of sectioning an inch out of the bumper longitudinally, then stepping down the accordions like a telescope--C C C , if that makes sense.

[acme911]

Originally Posted by madcorgi

Thanks, Andy. I'm actually toying with the idea of sectioning an inch out of the bumper longitudinally, then stepping down the accordions like a telescope--C C C , if that makes sense.

Looking forward to that idea. Couldn’t believe how much fluid is in the shocks when I did mine. I had to cut away a portion of the bottom on rear bumper to clear the GT3 muffler. Might go with the later model “smile” on the front. Overall I really like my cars profile now. Regarding bumperettes I had even toyed with idea of using 928,944, Boxster and some other makes. I’m working up a pair Smoked acrylic sunvisors while waiting for some suspension parts. Have fun!

Andy

[sugarwood]

Originally Posted by madcorgi

Still messing around with things. Drilled into the bumper shocks and hit hydraulic oil, then, a bit deeper, and into the inside tube, gas of some sort came whistling out--for quite awhile.

This means you have lost the damping effects of your bumper support?
The next mod I would do is put a flashing LED rear brake light!

[QueWhy]

Originally Posted by sugarwood

This means you have lost the damping effects of your bumper support?
The next mod I would do is put a flashing LED rear brake light!

Oh heavens, he’s compromised his 40yr old crash technology. I’m sure it will make a big difference when a bro-dozer sticks it’s winch through his back window.

Next time you park your 911 on the street(assuming you do such things) take note of where modern cars bumpers match up. About 75% of the time the 911s bumper isn’t going to be a factor, if you are lowered even a little that % goes way up.

I think a bumper tuck is going to be a winter project if I can find the time. I have an extra front bumper and set of accordions to experiment with and a 964 smile ready to go.

[AG81]

Originally Posted by madcorgi

[if that makes sense.

^
I am about to tackle mine. I appreciate you posting pictures after you cut thru the bump guard. I am headed in a similar direction only with much narrower bumper guards.