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