965 Front bumper install - the first challenges..
 

I started working on installing my new bumper today, and of course I ran into issues. The #1 issue was the exact same problem I had when I tried to install the IROC/RSR bumper, and that is "there's something wrong with my car." There's evidence that my car was involved in an accident early on in it's life; (I honestly think that's why they decided to do the widebody conversion) and I think that's what is contributing to my fit issues. The passenger side seems 'shorter' than the driver's side, so I have to cut material out of the inner lip of the bumper in order to get it to slide all the way back to the fender arch.

The second issue was a function of the first; there's a lip molded into the trailing edge of the top of the bumper, which is designed to notch into a similarly shaped area on the car. I have to modify the bumper to get around the bigger fit issue, so I can't take advantage of what would be fairly easy mounting.

So, to solve this, I welded 5 tabs on the front, and cut the lip off of the bumper. Now the bumper sits on those tabs, and when the time comes, I'll drill thru the bumper and the tab, and then weld nuts on the bottom of the tab to make a very easy install.

With the RSR splitter installed, this setup looks pretty mean. The bottom of the splitter is about 5" off the ground, but it sticks out pretty far; I will live in perpetual fear of curbs. Oh wait, I already do that :(

I was hoping to put off the oil cooler relocatoin project, but this bumper and the existing oil cooler location can't co-exist, so before I lock down the bumper setup, I'll do the new oil cooler setup.

All of the gory details are (will be) available at http://66.34.72.138/howto/965-bumper/index.html

http://66.34.72.138/gallery/image/2100294.JPG
http://66.34.72.138/gallery/image/2100294a.JPG

Looks good Thom. Clean install.
How is the front oil cooler going to be installed? Is another one of a different shape going in?
Another thought would relate to the underside shape of F1 cars, which create a venturi in the center. Will the handling/drag be affected without the lowest lip?
What about lightweight fiberglass panels to divert/cover up pockets where air could be trapped underneath the car?

Try dzus fasteners instead of nuts and bolts. Lighter, easy on and off, and they look cool

Well if anyone can make it fit, you can!

Hey tom you need the rubber smile, it also bolts under the hood, if you need some pictures of my car let me know, By the way the smile helps locate the bumper you will find it sits forward about a half inch, you use a c2 turbo smile, Kevin

Nice work Thom.
 

If you get in some more trouble i have around 100 pics on three different 964 front bumper mountings from mine, hopefully some can help you..

/Jocke

Why didn't I think of that?

I think this is going to look a lot better than the IROC.

I like the 1/4 fastener look too.