Modifying an IROC Fibreglass Bumper
 

Modifying an IROC Fibreglass Bumper, removing oil cooler "box" and shortening

I wanted to lose some weight by fitting fibreglass bumpers and I had a new narrow body IROC style bumper sitting in my garage. However, I wanted a different look and so I set about modifying it

Starting point
http://i226.photobucket.com/albums/d...c004173_o1.jpg

Marking up
http://i226.photobucket.com/albums/d...T/DSCN3847.jpg
http://i226.photobucket.com/albums/d...T/DSCN3849.jpg

No going back now
http://i226.photobucket.com/albums/d...T/DSCN3850.jpg

Making a mould of the centre section of a spare front valence.

http://i226.photobucket.com/albums/d...T/DSCN3844.jpg

The filler piece made from the mould

http://i226.photobucket.com/albums/d...T/DSCN3845.jpg

Bonding the filler piece in place

http://i226.photobucket.com/albums/d...T/DSCN3853.jpg

Filling the gaps and shaping thing up

http://i226.photobucket.com/albums/d...T/DSCN3855.jpg

Getting there
http://i226.photobucket.com/albums/d...T/DSCN3878.jpg
http://i226.photobucket.com/albums/d...T/DSCN3879.jpg

With some some primer filler
http://i226.photobucket.com/albums/d...T/DSCN3889.jpg
http://i226.photobucket.com/albums/d...T/DSCN3895.jpg

Trial fit.

http://i226.photobucket.com/albums/d...T/DSCN4136.jpg
http://i226.photobucket.com/albums/d...T/DSCN4133.jpg
http://i226.photobucket.com/albums/d...T/DSCN4139.jpg

Looks OK, but looks better if it did not extends forward so much
http://i226.photobucket.com/albums/d...T/DSCN4151.jpg

So...
http://i226.photobucket.com/albums/d...T/DSCN4164.jpg
http://i226.photobucket.com/albums/d...T/DSCN4167.jpg
http://i226.photobucket.com/albums/d...T/DSCN4168.jpg
http://i226.photobucket.com/albums/d...T/DSCN4169.jpg
http://i226.photobucket.com/albums/d...T/DSCN4171.jpg
http://i226.photobucket.com/albums/d...T/DSCN4166.jpg

Smoothing and shaping.
http://i226.photobucket.com/albums/d...T/DSCN4174.jpg

With some primer, again!
http://i226.photobucket.com/albums/d...T/DSCN4188.jpg
http://i226.photobucket.com/albums/d...T/DSCN4190.jpg
http://i226.photobucket.com/albums/d...T/DSCN4194.jpg
http://i226.photobucket.com/albums/d...T/DSCN4195.jpg

Also made a small splitter to finish it off. Made the plug in wood, took a mould and laid up the splitter in fibreglass cloth.
http://i226.photobucket.com/albums/d...T/IMAG0055.jpg
http://i226.photobucket.com/albums/d...T/IMAG0057.jpg

After running them in primer for a year, eventually painted.
http://i226.photobucket.com/albums/d...T/DSCN4444.jpg

And back on the car
http://i226.photobucket.com/albums/d...SC_0163mod.jpg

Nice work, certainly is different, looks 964-ish with brake holes. So I suppose you don't have an oil cooler up front. Is that a 964 smile?

sweet, the bumper, the aero mirrors, the color all work well together. Maybe some RUF wheels??

Nice work!
I'm thinking about shorting in mine too. Looks better when its not sticking out so much...

Well done. Bumper looks great.

I think it would also look good without the brake duct holes. They are useless unless you have ducts connected directly.

Very nice! Did you install a rear bumper to match?

Nicely done! I'm curious about how you made the mould from your original valence. Would you mind offering a brief description or a couple of links to point me in the right direction?

Thanks much

Thanks for the positive commets..

Standard Carrera 3.2 oil cooler in the fender, a second one on the the side to follow.

Yes, 964 smile

Yes, which also had to extensively modified to get it to fit just right.
http://i226.photobucket.com/albums/d...SC_0145MOD.jpg

The rear tail is also lightweight fibreglass as is the engine lid.

Stripped the old paint off (as it was not in good shape)

Waxed the metal

Painted on a layer of resin

Added several layers of fibreglass matting and resin

Prised it off when set

Im 5050 on the style- however it looks way better not hanging out so far- great work

Very nice - good work!

I really like it. As a car-obsessed child of the 80's, I love the look of impact bumper 911's. But if there was one thing I could change, it would be the bumper bellows front and rear. I always liked that the IROC rear bumper was essentially a nice, smooth, 1-piece rear impact bumper. I just wish we had a similar option for the front; a smooth, 1-piece front impact bumper. This gets us pretty close. Thank you very much. Now I must learn how to play with Fiberglass.

Wonderful, both front and rear.

Way cool!

Gives me incentive to fix my front Bumper.

Wow! That turned out great. The whole car has a very clean look that really like.

-J

That's a great looking bumper...I've been looking for a solution like this for a long time. Why doesn't anybody do a mold like this as a complete bumper?!?

Would you say you're a skilled fiberglasser? I'm wondering if this would be "easy" for the average joe (or average Doug) or if I'd just F it up if I tried it...

Do you have a profile shot of the whole car?