Well, let me preface this entry with this: I have no experience with autobody techniques. 0%. I just used Bondo for the first time about 3 months ago. So, that being said, if you have a brain larger than a chimp with downes syndrome, you can do this exercise.

(My apologies to anyone out there who have any chimps with downes syndrome.)

I wanted to shave the front end because I just think it looks clean as hell and who the hell needs turn signals or foglights anyways?



There are the tools I used. I think in total, the body filler goodies cost me around 100 bucks but I only used about 15% of it so do the math.

Fusor 142: This is "extreme body panel repair". It has a work time of 90 seconds. Yeah, um, first mistake getting the "super fast" curing Fusor but fuck it, I can work fast.

Polyflex: This is a bendable filler that should be used as an aftercoat. Works just like bondo.

Versa-tool: It's a glorified soldering iron but it has 19 cool-ass tips that are PERFECT for plastic welding. I found it at Micheals (craft store) for 30 bucks, laid down the 50% off coupon in their mailer at the front of the store and was on my way with a sweet 15$ plastic welder.

Cut-off wheel, belt sander and jig saw are optional but certainly help...

Let's get cutting. Mask off your front bumper and git to ruining a perfectly good bumper:




Voila:


The cut pieces:


Now, roughly measure the cut area and transfer to a rear doner bumper. I have heard that you can take from the center but I cut on the curve so I tried to grab from the rear curve as well...


Now, once the pieces are cut, make sure everything lines up and, most importantly, make sure the main bumper line, lines up as well. Turn the soldering iron on and wait for it to get hot. Once it's ready, place the cut piece on the bumper and literally melt the two together. Make sure both pieces melt together as this will create the strongest bond. Don't be afraid to make shitty "welds" as yer gonna sand over them later. The main goal here is to make sure both pieces melt together. I'f you've ever welded, yer looking for a "roll of nickles" here in your welds.









Now, take some plastic from the side of the doner bumper to fill the turn signal holes if you want... I'm grafting in something different later *wink*



This is where the belt sander is handy (and after using this fucking thing ONCE, I was happy to find another use for it.)




Like a glove...


Now, once the welding is done, crank out the fusor and go over all of the welds and fill in the holes that weren't welded. Also, flip the bumper over and glue up the seams. Be generous here.

Once it's dry, sand it with 60 grit.




Now, sand some more with 150 grit. Now, it's time for the polyflex.



Skim thin coats, let dry and sand some more. The goal here is to sand away most of the polyflex. Notice the low spots that are now filled? w00t!



Once everything is smooth, slap on some primer and go have a beer =)

This entry was posted by JKREW, on Monday, April 2, 2007. You can leave your response.