chaotichoax

iTrader: (149)

I decided to tackle this job myself

I have no bodywork experience but I'm always down for a challenge

the bumper was bought from a car in NYC and it had a lot of battle scars hence the bondo everywhere

just needs final prep work and paint



how to: evo viii bumper nose chop


note: there are many ways to go about this, this is how I did it

note 2: if you aren't familiar with the term plastic welding - google it


tools/materials required:

heat gun
dremel
sharpie
soldering iron
sandpaper (150 grit/1000 grit)
1/8" thick abs plastic sheet
fiberglass strips
fiberglass resin
bondo
clamps
plastic strips (plastic welding material - cut thin pieces off the cut out bumper triangle)


1. cut the triangle out of the bumper - when you do the top leave as much as you can to keep the top connected (you'll only be able to leave a very thin section)

2. take abs plastic sheet and place it under the cut out triangle hole - trace the cutout on to the sheet with a sharpie

3. begin cutting the traced shape out - be sure to leave material around your trace lines (you can always cut more off if needed)

4. test fit piece until it fits relatively snug in cut out area

5. clamp piece into cut out are and if it isn't perfectly shaped to the cut out use a heat gun to mold the piece - towards the front of the bumper required the cut out piece to be slightly sloped down - *this step may not be needed for everyone (all depends on your cutting technique from step 1)*

6. once satisfied with fitment and shape of your cut out piece begin plastic welding piece into place
a. do the underside first and then do the top side - use small strips of the triangle you cut out as your welding material

7. cut out 3 fiberglass strips approx 4" longer than the underside of the cut out on each side
a. apply resin to the underside and lay down your first strip apply resin and repeat two more times

8. sand down the topside so the plastic welds are even with existing bumper material - pay close attention not to sand too much of your welds

9. sand surrounding cut out area of existing paint with 150 grit sand paper since you want to be able to spread the bondo slightly beyond the cut out

10. rough the topside of the cut out material with the 150 grit sand paper for added adhesion with the bondo
a. apply bondo in a thin layer (recommended being no more than a 1/4" thick when completed so less you use the better)

11. sand the bondo with 150 grit sand paper - often taking your hand and sliding from one side to the other checking for unsmooth areas
a. skip to 13 if the cut out is smooth

12. apply a second layer of bondo if necessary (keep in mind you want it to be as thin as possible when complete)

13. wetsand area with 1000 grit sand paper to achieve a smooth finish

14. back to focusing on the very thin top section of the triangle
a. sand the edges smooth with 150 grit sand paper as carefully as possible
b. if satisfied wetsand with 1000 grit sand paper
c. if not satisfied with how this came out you can just cut the thin section out and have the two top sections disconnected (hood latch is right there and you can't see this part with the hood closed unless you get down and look)

15. that's it - take it to a paint shop

more pictures (from camera phone)





this is the underside...three layers of fiberglass for rigidity




painted

Evolution IVGSR

iTrader: (42)

Sick man I just barley did one for a Friend. I am going to do mine own next. Can't wait to see how your whole car looks when its done

Joemflsxe

iTrader: (5)

Nice, I've been wanting to do this really bad but wasn't crazy about how much people were saying it costs to have done. Can't wait to see how it turns out!

Samuelsan

iTrader: (1)

I'll have some pics of it on tuesday or so

mrboost05

iTrader: (25)

sick i cant wait to see it all done i love your car as it sits now and your photos are always on point

NY Evolutionary

iTrader: (25)

I have always thought that an VIII bumper with a Do-Luck lip, and the triangle cut out is THE hot set up for the CT9A!!!!!!! Can't wait to see it done, I think it will be the first WW that I have seen like this.

CJ2X

iTrader: (4)

Bad move, IMO.

4G63kevin

iTrader: (16)

i like. im planning to do something like this soon.

unsungboxer

iTrader: (7)

ix front bumper > modded 8 front bumper

CAD EVO

iTrader: (22)

hot asian chick > hot blonde asian chick

Does it really matter?

MMMR0820

iTrader: (19)

Why'd you decide to go with the VIII bumper with chopped nose? The IX bumper isn't doing it for you any more?

Joemflsxe

iTrader: (5)

IX bumper just doesn't flow with the car IMO, too much going on maybe? VIII bumper with a clean lip looks really simple and flows better on most cars, and with the nose cut it really has a clean look.

Highjack - Anyone want to trade a IX bumper with SE lip for a VIII bumper? hah!

edison

iTrader: (9)

cant wait to see the finished product

EvoRob22

Looking nice. Great job for your first attempt. VIII Bumper > IX Bumper IMO

scorke

iTrader: (18)

NO!

Scorke