Boxster Project 68 : Front Bumper

[Wayne 962]

Anyone got any questions on Project 68 - Front Bumper for your 986 Boxster, 987 Boxster, Cayman, Carrera 996, or Carrera 997?

Here's a back link to the original article: Pelican Technical Article: 68-BODY-Front_Bumper_-_Wheel_Liner

-Wayne

[frobenius]

I've read the very helpful (makes me inclined to pick up the Tips manual)
Boxster bumper removal section and there are few details that are different with an '07 Boxster S, but in general the procedure is fairly close. There are 3 screws underneath the front trunk cover, 9 on the bottom, and 2 each on the marker lights. I've removed the front wheel well liner as well. Yet the bumper will not come out - so how powerful are these "strong pulls"? It seems to be stuck in the area by the hood/headlights. As you mentioned, the bumper isn't cheap so I'd like to not screw it up. Any help would be very welcome.

[mcmike27]

Wayne, I have a question....our car came with the 'Steel Boomerang' bottom bumper cover. Are these bolts/screws integrated into the cover where the normal screws would have gone or are there still the original screws underneath the 'boomerang'. It looks like on my initial inspection that they are integrated and the whole unit will drop off when I remove the bumper in the spring for my annual debris clean.

[s_wilwerding]

I actually have a question about the back bumper - I had a little issue with my new exhaust at the track, and the U-pipe fell off and started melting the old bumper. I ordered a new one and had it painted - little did I realize that the sections where the frame come through (that are covered by the bumperettes) are not cut out of the new bumper.

My plan is to take the old one off and make a template for the cuts on the new one (should have done this BEFORE it was painted, but oh well). The big question is, what do I use to cut the bumper? Obviously I have a little leeway since the bumperettes will cover it, but I would like to cut as accurately as possible.

[dad911]

Steve, it cuts easily. On the spec boxster, I cut in cooling holes with small holesaws in the corners, then a jigsaw in between.

[harryrcb]

Originally Posted by s_wilwerding

I actually have a question about the back bumper - I had a little issue with my new exhaust at the track, and the U-pipe fell off and started melting the old bumper. I ordered a new one and had it painted - little did I realize that the sections where the frame come through (that are covered by the bumperettes) are not cut out of the new bumper.

My plan is to take the old one off and make a template for the cuts on the new one (should have done this BEFORE it was painted, but oh well). The big question is, what do I use to cut the bumper? Obviously I have a little leeway since the bumperettes will cover it, but I would like to cut as accurately as possible.

I used a good quality box cutter, cuts like butter and the lines are straight

[Wayne 962]

Originally Posted by s_wilwerding

My plan is to take the old one off and make a template for the cuts on the new one (should have done this BEFORE it was painted, but oh well). The big question is, what do I use to cut the bumper? Obviously I have a little leeway since the bumperettes will cover it, but I would like to cut as accurately as possible.

This is relatively easy with the cutting tool that I use in the book. It's just a Dremmel attachment. Work slowly and take your time, as these bumper covers can be $900 EACH depending upon which year / model you have. And that's not even Genuine - that's aftermarket (which is still as good quality as the originals).

These bumper covers are probably what I think are the biggest margin part around for the manufacturers - it's tempting to start knocking off repros.

-Wayne

[Wayne 962]

Originally Posted by harryrcb

I used a good quality box cutter, cuts like butter and the lines are straight

On my particular bumper, that would have been a bit difficult - they are about 1/8" thick or so. With materials that thick, you tend to want to use more force than is recommended to cut. When that happens, the possibility of slipping and cutting yourself becomes much greater. I'd recommend the Dremmel tool (wear safety glasses), as you can really get some fine detail without using any force.

-Wayne

[Wayne 962]

Originally Posted by mcmike27

Wayne, I have a question....our car came with the 'Steel Boomerang' bottom bumper cover. Are these bolts/screws integrated into the cover where the normal screws would have gone or are there still the original screws underneath the 'boomerang'. It looks like on my initial inspection that they are integrated and the whole unit will drop off when I remove the bumper in the spring for my annual debris clean.

I'm not sure which cover you're referring to? Can you let me know which year you're talking about? Is it similar to this one?



-Wayne

[Wayne 962]

Originally Posted by frobenius

I've read the very helpful (makes me inclined to pick up the Tips manual)
Boxster bumper removal section and there are few details that are different with an '07 Boxster S, but in general the procedure is fairly close. There are 3 screws underneath the front trunk cover, 9 on the bottom, and 2 each on the marker lights. I've removed the front wheel well liner as well. Yet the bumper will not come out - so how powerful are these "strong pulls"? It seems to be stuck in the area by the hood/headlights. As you mentioned, the bumper isn't cheap so I'd like to not screw it up. Any help would be very welcome.

I'm not aware of any additional fasteners in the front. Here's a diagram from the parts diagrams from Porsche, seems to match my memory:



Is one side moving more than the other?

-Wayne

[mcmike27]

Wayne, we have a 98 986 stock and under the front lip of the front bumper skin is a boomerang shaped piece of steel that came with the car when it was delivered to my wifes Uncle in 1998.

Here's a description I found:

Due to the nasty dip leading from our offices to the street, Performance Products equipped our Boxster with its "Boomerang" protection plate. Shaped like its name, the Boomerang is a stout metal plate that fits the lower lip of the Boxster's nose. It has saved us untold damage to the radiators, front condenser and front spoiler. I know this because the Boomerang bears the scratch marks of countless driveways, parking berms and curbs. Get one, now!

It's screwedin and it looks like it 'shares' the original factory screw locations. I am going to do my 1st spring cleaning since we have owned it and wanted to know if yo have come across a similar device before I start unbolting and unscrewing things to get to the front rads to clear them of any debris.

Thanks

m2

[Wayne 962]

Nope, haven't seen a similar device, but the description is a bit ambitious. The front bumper cover does take a lot of abuse, but there's really not too much threat of the catastrophic damage that is mentioned in the description. I don't think that product is available any more, as I haven't seen it or even heard of it before you mentioned it.

-Wayne

[frobenius]

Originally Posted by Wayne at Pelican Parts

I'm not aware of any additional fasteners in the front. Here's a diagram from the parts diagrams from Porsche, seems to match my memory:



Is one side moving more than the other?

-Wayne

Wayne,

Many thanks for the help. The diagram is quite useful. Finally, winter broke here and I could get back to the Boxster. The screws, for the most part, are pretty obvious. The key here lies in part #25 on the diagram, which are two slotted clips that you can hook a string or wire around and pull out to free the top part of the bumper. After that, it is pretty straightforward.

Frobenius

[JMatta]

I believe this is the boomerang he is referring to. I did a Google search and it came up at another supplier website (which I won't mention in respect to PP).

[mcmike27]

This is EXACLTY the item we have on our 98 986 my wifes late Uncle had it installed when he picked it up from the dealer in So Cal when he aquired the car. In order to take off the front bumper cover must I remove this device? It's hard to tell if it 'shares' the same screws that attach the bumper cover to the front end? At 1st glance it almost appears that it is 'integrated' and can still stay on without having to unscrew it.

[mcmike27]

Here is another pic of this device. Sure enough it's the exact one we have.

[jittsl]

That boomerang does not share any fixings with the bumper. You will in fact have to remove the bumper to remove the boomerang.

[Wayne 962]

I think this device attaches to the bumper itself, so you can just remove the bumper, and it should come off with it.

-Wayne

[Wayne 962]

Those boomerangs are no longer available. If someone has one they can lend to me, that would be great, as I will have them manufactured.

-Wayne

[NICO67]

Originally Posted by wayne at pelican parts

anyone got any questions on project 68 - front bumper for your 986 boxster, 987 boxster, cayman, carrera 996, or carrera 997?

Here's a back link to the original article: pelican technical article: 68-body-front_bumper_-_wheel_liner

-wayne

hi.
Simple question. Does 2002 turbo 996 front bumper and headligths fits into 2002 986 boxster?