Project seems weird ? Keeps reading.

It's been a while that I look for a front lip to balance the look of that ''damn'' big Evo8 wing on the trunk. At the begining, many options were offered. I know that Road Race sells one, and no offense to them, but at a price of 400$ + 200$ of shipping without paint for add-on lip, it's a little bit expensive for an fiberglass part.

RRM FRONT LIP.




Like many others, I've looked at ebay and decided to order this lip, not the sexiest but thought it would do the job. Of course I didn't seen that, the Lancer on the picture is an European version and the lip would not fit. Great seller, I was refunded.

EBAY FRONT LIP


I've started to think that my best bet would be to make it on my own. I've read a lot of thread about how to make custom part. Then I found a guy that had builded a complete bumper for his Acura RSX with paper pulp. Paper is cheap, easy to work with, and If it doesn't work, I won't waste my money.

Here's the story begins :

 

First, sorry for the bad quality picture, they were taken with an old Ipod 4.

My setup :

Only 4 things... Paper, white glue, paintbrush and patience.



The first step I've made is to remove the front bumper. Then, I put some tape around the OEM lips.

 

Great work! it looks very nice!

 

I've put some kitchen plastic wrap over the OEM lip to protect it from the glue. I've cut some paper strips and soak them in a mix of 70% glue and 30% of water. The goal is to get an ''footprint'' of the OEM lips.



I also take house isolation sheets foam and marks the exterior size of the bumper. I cut it and makes it fit around 3 inches outside.



Little side view

 

Thanks evo2809, but I'm far away your project ! haha

 

Then goes the expanding foam. The foam will link the paper footprint of the OEM lip and the blue isolation foam at the bottom.




Expanding foam will link the 2 parts and when being cut (easily with knive) will make the shape of the lips.

The lip with the bumper removed.

 

Little test fit, bumper back on the car. I need to go to work after all...



Start to cut the foam.




Little mistake here, I forget to take picture of the next step but here's the result. I've wrap the expanding foam and the isolation foam with paper mache. Again fit test...

 

Ok, so this will the my last post for today, this is where I'm now. The lip is completly cover with wall filler. I'll sand it in the next days to get the most perfect shape possible.

I wasn't supposed to go that way in the begining but, I'm looking forward to use this shape as a mold for fiberglass. I'll keep updating.

 

Wow this is really cool! I cant wait to see how it turns out! Keep it up!

 

i've been thinking about doing this exact same thing but with fibreglass instead...but my problem is the mounting hardware keeps breaking off...there's nothing visually wrong with my lip.

 

Woah, okay that looks awesome so far. ^Like crans, I've been thinking about doing something like that with fibreglass.

 

A little bit of sanding tonight.




Finally I've decide to use this part as a plug and go with fiberglass.

I've purchase all the stuff needed this afternoon.

First time I'll do this... hope it will be fine.

The kit :

 

Thanks guys for the comments... I appreciate.

And if some of you did fiberglass before... any advice ?

I know a little bit where I'm going but any tips are welcome.

 

lol, yeah...if anyone knows how to make fibre glass look really nice without too much sanding, I need to patch part of my boat.

 

First coat of resin applied.



Objective for the rest of the day : Apply 7 coat of wax and the 3 coat of pva. After that I'll be able to start fiberglass.