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?

I agree, looks great!

Thanks for the compliment.

The demand is probably not high enough to justify a business investing in the work to make a bumper and the mould.

I am just a hobbyist and take my time trying to get it right.

It is probably not the first project in FG you should attempt, but if you are good at bodywork repairs and have some knowledge of FG you could be OK.

Certainly, this one is of the car on its track BBS RS split rims.

http://i226.photobucket.com/albums/d...T/DSC_0420.jpg

Mark

Thanks Mark! Really looks great. I may have to give it a go...I really want to lighten my 912E, but most of the RSR style bumpers would just look ungainly on it. Yours is visually weighted more appropriately, IMO. And I just can't find anything else that will work the same (that won't cost a fortune as they're bespoke pieces).

Cheers!

I really like this too. I'll have to add it to the winter projects list.

WOW>>>> Great job. I luv the look. Almost like an SCRS but in narrow body.

http://forums.pelicanparts.com/uploa...1345076266.jpg

That's exactly what I was looking for back when I had my '74.

http://forums.pelicanparts.com/porsche-911-technical-forum/435333-does-anyone-make-simple-clean-fg-bumper-74-77-911-a.html

Glad I found this thread (thanks Will!)

Still have a hard time believing there isn't a "market" for a bumper such as this. It's only a small portion, but if this thread (and mine linked) are any indication, I have to believe it would sell.

...maybe?

Agreed!

I just bought a RUF replica for my SC, but I'm not sure if it's what I really want. The above or an SCRS replica would be on the top of my list.

Not a problem.

I've wanted to backdate my SC for a long time. I hate to be this guy, but seeing as how long hood prices are dragging SC values up, I don't like the idea of doing any major modification that can't simply be bolted back. Additionally, I'm a child of the 80's, and the impact bumper look tugs at my heart strings. My only problem with the impact bumper look are the bumper bellows. I feel this is a way to keep the factory look, only improving it slightly while taking weight out of areas that will greatly enhance the way the car feels.

I would actually like to backdate my car (..er, maybe a 911..), but that's considerable expense. What I like about what Mark has done is it would look really good on a clean, un-spoilered car (my preference). These RSR bumpers with their big airboxes just look ridiculous unless you have filled out fenders and a tail to match.

And yes, since I have a 912E that some people are calling rare and suggesting I don't change it too much, it might be cool to do this to it so I can have a "personalized" car that can be brought back to semi-original specs. (...even though one of the car's P.O.s has already "ruined" it by putting on fiberglass fenders.. :rolleyes: )

that bumper looks great!!!! good work, how has the middle section held up?

Here are a few track picks from a couple of weeks back (Dec 20 2013), that show the bumper is holding up fine.

http://i226.photobucket.com/albums/d...ps1123a984.jpg

http://i226.photobucket.com/albums/d...ps9260a50b.jpg

http://i226.photobucket.com/albums/d...ps2c6371b3.jpg

There is an issue with extensive stone chipping, which is a function of the shape and ride height, which you have to live with if you drive it!

I have had to replace the "splitter" on the lower edge a couple of times, but I always regarded it a "sacrificial".

And one of the back to finish with.

http://i226.photobucket.com/albums/d...ps230da9f7.jpg


Mark

Beautiful work!

Fabulous work and talent! Kudos

Mark,

Looks awesome. How's the WaveTrac?

Ahh, Brands Hatch. Nice work on the bumpers.

looks like mad skillz with fiberglass, nice.

BTW, your license plate changed from V 9 to VSU379 ;)

Hi Will,

Taking it easy I don't know it's there, but with more enthusiastic driving I can feel it locking out of corners. The car had a fairly neutral balance with the way I drive it, but it now has a bit more oversteer. I will add a bit more toe and camber at the rear and experiment some more.

Mark

That is what I would like to do if I were better at fiberglass work.
This is the best option I have found but very expensive.

911 SC RS Front Bumper (Narrow) | 911 SC RS | Products | Eb Motorsport

Coolio,

My New Year's resolution is to get my winter projects done in the winter so I can drive it in anger this fall.

nice
 

It's easy to see you took some time and put alot of work into it! Very nice, not your everyday IROC look with very nice fit and finish!
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