DIY Custom Lip Discussion Options

[ZGear]

So I've been contemplating and researching on how to build any body parts from scratch. Truthfully, I really don't like any of the existing front lips for a pre-faced bumper. They are all either Jay Leno's chin looking like or too over the top. I've also narrowed down to the style of the lip. Just like my Euro lips, they will be an add-on from the bottom down, hence universal to when I change front bumpers.

This is what I've come up with

Step 1: Trace the mounting plate with the bottom of the bumper. Keep in mind to measure the indentation space for the mounting brackets

Step 2: Build and style crazy ideas with cardstock/cardboard for lip design.

Step 3: Assemble the lip and reinforce with tape?

Step 4: Fill the backing with expanding foam for reinforcement. If needed, spray foam on the front side to get rid of any geometrical shapes and have it appear smooth. Would rather have foam than putting on huge amount of bondo in the end to smooth out the surface.

Step 5: Sand down the foam to desired look. (Yes, keep in mind to buy sandable foam)

Step 6: Test fitment again.

Step 7: Time for fiber glass! Fiber glass both side for structural integrity.

Step 8: Wet sand and dry sand the fiber glass product to desired specifications.

Step 9: Test fitment again.

Step 10: Add bondo/spot puddy for the last and final smooth preparation.

Step 11: Primer and sand.

Step 12: Ready for paint and clear coat!

Just the basic layout, don't want to get too technical yet. Anyone have experience with fiber glass and expanding foam? I heard that the resin may shrink the foam quite a bit, another reason why I may have to cover it with cardstock once the foam is sanded down.

Also, anyone know what the height difference is with and without side skirts? Wouldn't matter if the car was lowered or not because it's only the extended height from the door down.

So far, I have the mounting plate mock-up done and will keep an extra copy in the near future use. Yes, I will be building more custom personal lip designs for myself and maybe a few locals here.

Any critiques, other opinions, or question/answer?

[playr158]

a) design on paper
b) adhere foam block to bumper
c) trim to get your shape
d) cover in tin foil
e) apply mold release wax
f) lay fiberglass
g) sand

I wouldn't be using cardboard for anything, its kinda just a pain in the butt.

this is a good reference
http://www.j-body.org/forums/read.php?f=6&...674&t=54674

This post has been edited by playr158: Mar 9, 2010 - 2:44 PM

[TokuzoST185]

A different method (one I'm using for my halo costume) is to build with oil based clay. This way if you mess up you don't need to start on a new piece of foam, you just add clay; plus it is way easier to work with. Then you mold that in silicone, make a two piece plaster hardshell, and then slush cast the mold in urethane. Each step requires a releasing agent, but this is much easier than building out of fiberglass mat. If you have any questions shoot me a PM and I'll let you know more detail on how to do this. It's not hard at all, just very time consuming. And this way, if your lip turns out to be a popular one, you now have a mold to cast and sell them.

[SwissFerdi]

I wouldn't mind seeing an example similar to the Seat Leon Cupra lip that some members here are rocking.

[ZGear]

a) design on paper
b) adhere foam block to bumper
c) trim to get your shape
d) cover in tin foil
e) apply mold release wax
f) lay fiberglass
g) sand

I wouldn't be using cardboard for anything, its kinda just a pain in the butt.

this is a good reference
http://www.j-body.org/forums/read.php?f=6&...674&t=54674

Damn! They went all-out on that NSX.

I've followed some enthusiasts' thread builds, even youtube has quite a load out there now, but one thing has strayed me from foam blocks. Almost each build needed a heated wire foam cutter to get the foam cut into shape. Is there an easier method? I've seen home-made wire foam cutters, but I don't trust myself to build one yet. I also was thinking of going to my local pawn shop to pick-up a cheap power tool cutter, but because the power tool cutter moves up and down it would be very hard to cut at certain angles.

Also wouldn't the many creases from tin foil cause more distortion when laying the fiberglass? Or would I have to neatly cut out the tin foil to shape and apply it to the mold or body panel? I also read somewhere that paper/metal/wood was a lot easier for fiberglass to adhere to compared to foam......hence why I chose paper, the lighter of the 3. Please advise, I'm still learning.

A different method (one I'm using for my halo costume) is to build with oil based clay. This way if you mess up you don't need to start on a new piece of foam, you just add clay; plus it is way easier to work with. Then you mold that in silicone, make a two piece plaster hardshell, and then slush cast the mold in urethane. Each step requires a releasing agent, but this is much easier than building out of fiberglass mat. If you have any questions shoot me a PM and I'll let you know more detail on how to do this. It's not hard at all, just very time consuming. And this way, if your lip turns out to be a popular one, you now have a mold to cast and sell them.

I do agree with you on VERY time-consuming, especially a newb like me into the custom world. I've contemplated with making a mold many times, why? I don't really know, but I do know that in the end it would be really easy and cheap to replicate it with the mold.

My only concern would be switching between too many polymers and hardeners that it could get costly, ofcourse it's the cost of being unique. My thoughts were to experience with a build first and then focus and refine my skills with a mold later down the road. Also,......... on the Halo costume. I also followed some of the 405th's Halo Costume builds. I was gonna attempt to build a Hunter suit.

I wouldn't mind seeing an example similar to the Seat Leon Cupra lip that some members here are rocking.

Any pics? What inspired me to build a custom lip was a picture of a red GT. It had the Home Depot lip, but in a very creative and awesome looking way. It was mounted up front where the bumper met the fenders and went all the way around towards the middle of the bumper. The difference was that it was cut in two pieces and at the middle of the bumper it curved outward instead of the usual dropped curtain look all round.

[playr158]

Start out with a knife get your rough cuts, then guitar string can help to get even closer, after that sanding.

[youseman]

i totally agree ZGear, im dead interested to see how this turns out