My front bumper re-design
 

I have been struggeling to keep my engine cool enough on track events.
Before installing a front center mount oil cooler, I thought I could try move my 2 fender mounted coolers in better position, and also open up for more airflow.

I bought a used front fender, that also will provide more downforce, as a core.

I have been inspired of the open ducting that the 993 GT2 evo front fender has.

http://i867.photobucket.com/albums/a...psvkan1w7a.jpg

This is my starting point

http://i867.photobucket.com/albums/a...pspx8f1tub.jpg

Then I started to cut out opening :-)

http://i867.photobucket.com/albums/a...psbfb6ymob.jpg


Then I started to section out the openings...

http://i867.photobucket.com/albums/a...psdu2sfvdl.jpg

Then a little trial fit...

http://i867.photobucket.com/albums/a...ps86kefhht.jpg

Design comes along as I go :-)

Found out that the small ducting could be used for cooling duct for the brakes.

Needed something square'ish to round tubes.
Used some plastic soda bottles, cut then in half and used the top section.
Stuck then on a 2/4, to create a mold.
An old rear shock, was used as a mold for the round tube :-)

http://i867.photobucket.com/albums/a...psdyvsa6rz.jpg

Then some more cutting and trial fitting.

http://i867.photobucket.com/albums/a...ps1fqffbdr.jpg
http://i867.photobucket.com/albums/a...pssxxm0kjf.jpg

Brake air duct completed

http://i867.photobucket.com/albums/a...pst6fp0jlh.jpg

Finally getting closer to where I want to be...

http://i867.photobucket.com/albums/a...psaqprikox.jpg

And you even used a norwegian Solo bottle.

Awesome effort! I like it.

Hehe Jesper, you got that detail :-).

That looks terrific, Trond.

Thanks :). Just nice to give some personal touch to it :)

Wow that is great work! Looks very good.

pretty slick there Trond

wish I had your fiberglass skills (or any others for that matter!) - I've still got to figure out a way to mount my brake duct hoses to the back of my rectangular AIR valance

looking forward to your finished product - keep up the good work

I like that, should look great also, keep the pic's coming

Thanks guys. I will see if I can do some sanding and filler tomorrow.
But the weather is sooooo nice here by the coast in the south of Norway, so spend much time out in the boat or in the sea :-)

Will keep pictures coming :-)

One more round of spray filler, and I think it will be ready for paint.

http://i867.photobucket.com/albums/a...psnlfvuozv.jpg

Nice work there Trond! I suppose you're too stubborn to go with center oil cooler as most others suggested?!? To be honest I'd be surprised if you still have overheating problems with your mod'd front bumper.

Mike, it's not that I am stubborn, just like to try out new ideas :D

Yes, many has suggested front center monted cooler, many has also said ithe 2 I have should be enough.
If I'm failing, it will be a lesson learned and a hell of a lot work for nothing :D

But looking at the GT2 EVO, they did it without center mounted cooler.

I have also repositioned the coolers and cleaned them

Those are some big ol air gulping holes. I think you'll be fine with regard to cooling. I have coolers in each side as well but my next bumper makes the center mount more handy so that's what I'm doing. Not because I need to though. You'll get it right I think.

Painted. Tested out my new Eastwood HVLP paint gun

http://i867.photobucket.com/albums/a...psyqjywyhm.jpg

Will make some direct ducting on the oil coolers, then final installation :-)

Nice work :)

Now I think it will breath more :-)

http://i867.photobucket.com/albums/a...psk2nrv7sq.jpg

http://i867.photobucket.com/albums/a...psdjmx7jv0.jpg

That looks awesome!!!

cooling issues done

Wow Trond - very impressive work - looks great and I bet it works, too!