curtis
(Space Blanket from NASA plumbed into the attic)
06/29/05 12:32 PM
Shortened rear bumper with alum support

Well a few weeks ago snagged a aluminum rear bumper from a 760 turbo Volvo. I wanted to do this now because I have an evo suspension set on the way and want to get the ride high set once and for all.

This so far has been one of the easiest fabrication exercises yet.

I removed all the 10mm bolts that hold the side to the body then the 14mm's in the aft of the trunk. She fell right out. First thing I did was weigh it my 50 pound spring scale instantly maxed out so I went to the bath room for the house scale.
I removeded about 30 10mm's bolts and pulled the heavy bitch off the cover. About 30 % of them broke off from rust.

Now for the mounts. I spoted all the spot welds with a center punch the started drilling 3/8 holes (11 on each mount) They fell right off then reinstalled them on the car for fitment for fitment. They are perfect the volvo bumper slides right into them.
I've started cutting the ends of the bumper off. This is some super hardened aluminum. My diamond wheel usually eats through aluminum but this stuff is just dusting off. I may run into town and use a band saw at my buddies shop.

As for the mounts for the bumper cover. Im going to take some light weight sheetmetal and bend and rivet it to the bumper and zip tie or use some off the plastic insert screw thingys that mitsubishi loves to put on cover plates.

When I'm done this thing should weigh about 20 pounds total including the cover. And not be rusted out. Both ends were eat up from rust and I have a pile of rust scale in the drive way the size of a basketball.


More photos as progress comes along.






blacksheep
(Baraqsheep)
06/29/05 12:35 PM
Re: Hear I go again. Alum rear bumper

mad fuckin scientist, yo!

steveGalant VR4.org Administrator
(Key Fob Guy)
06/29/05 12:40 PM
Re: Hear I go again. Alum rear bumper

werd

powerplay
(Yes Man)
06/29/05 12:42 PM
Re: Hear I go again. Alum rear bumper

Curtis, that is great. My rear bumper support is totally rusted out. Almost from one side to the other. All you have to do is tap on the cover and piles of rust falls out on the ground. Please keep us informed how this goes. I think this would be a great upgrade for our cars.

steveGalant VR4.org Administrator
(Key Fob Guy)
06/29/05 01:01 PM
Re: Hear I go again. Alum rear bumper

Quote:

Well a few weeks ago snagged a aluminum rear bumper from a 760 turbo Volvo.




I bet the owner is pissed though


cheekychimp
(Director of Housing and Urban Development, and carbon/kevlar balls)
06/29/05 01:02 PM
Re: Hear I go again. Alum rear bumper

Curtis,
Way to go man. Weight Reduction and arguably safer than the USDM supports. Volvos are some of the safest vehicles in the world.

Paul.


curtis
(Space Blanket from NASA plumbed into the attic)
06/29/05 02:12 PM
Re: Hear I go again. Alum rear bumper

Well I've been cutting and cutting and cutting. This bumper isn't cast but some type of aluminum extrusion with some hard ass alloyed stuff mixed in the aluminum. I have one side cut and tomorrow hopefully I'll have it back together.

Well I'm going to the pool with my daugher, Its to hot for this modding right now.


**DONOTDELETE**
(Unregistered)
06/29/05 03:47 PM
Re: Hear I go again. Alum rear bumper

Nice firewall, I think I need one of thems. Is that aluminum also?

curtis
(Space Blanket from NASA plumbed into the attic)
06/29/05 03:57 PM
Re: Hear I go again. Alum rear bumper

Yea its some aluminum I had in the garage. Its kind of a pain to fit even with a templete made of cardboard. But it cut down on noise coming from the exhaust.

curtis
(Space Blanket from NASA plumbed into the attic)
06/29/05 08:34 PM
Re: Hear I go again. Alum rear bumper

Update
I didn't tell you just originally because most of you I'm sure have never had the rear bumper off. Its flat across (no arch at all like most bumpers) I'm going to have to modify the foam backing to work. For the rest of you that want to do this project to save weight or just to replace the rusty pos, you can go to a metal recycler or a supply house and get a 6 x 3 inch (a little over 4 feet long) box alumium tube or channel and build your own a lot cheaper and easier than raping a volvo at the junk yard or at the mall.


**DONOTDELETE**
(Unregistered)
06/30/05 06:26 AM
Re: Hear I go again. Alum rear bumper

Buy the way I forgot to tell you guy's here that I work for Hydro automotive. we make alum bumpers if this is something people need
hell i can make them at work. Welding,cutting, you name it I can do
it for you. for an small fee(parts,money,beer)I'm easy just like an Sunday morning. just hit me up .


curtis
(Space Blanket from NASA plumbed into the attic)
07/02/05 04:26 PM
Re: Hear I go again. Alum rear bumper

done

It was simple but took alot of time to mess with.

I riveted a piece of 3/8 aluminum channel (home depot racing). Took my time trimming and fitting and trimming and fitting etc.
I removed the tabs and bolt on side assemblies and used a screw behind each light to attach and used the two bolts underneath the sides and one screw in the mid on top. I cut the cover back at about 1/2 inch from the lip on the top so it would line up with the lights. The one thing I hated doing was to beat in the corners in the rear of the trunk along with the spot weld lip but it had to be done. When I get my tig welder wired up I'll go back and weld in some new metal.

Now to complete I have to modify the lights some and get a few cans of spray foam because I said screw the 9 pounds of foam insert and the time to cut that shit up. The total assembly is 18 pounds which is a great weight savings.

When cutting everything use a pair of calipers and lock them in place and scripe a line and you'll be good.
Now for pictures.











**DONOTDELETE**
(Unregistered)
07/02/05 04:53 PM
Re: Hear I go again. Alum rear bumper

Simply put, that looks better than rear jdm bumpers. SICK.

Polish
(Dr. Pilosh Haagenscodyberger)
07/02/05 05:22 PM
Re: Hear I go again. Alum rear bumper

Awesome man. What year and exact model did it come from. I will be doing this for sure. I have a weight reduction project in process also. I just posted about it actually. So the weight savings was a good 50lbs you'd say?

a_santos
(Brasileiro Turbinado)
07/02/05 05:31 PM
Re: Alum rear bumper Done with pictures

Nice work. So let me get this straight, you just recut the wheel arch on the bumper further in?

It looks very nice. Do you think it can be done with the front bumper as well, do bring it in closer?


curtis
(Space Blanket from NASA plumbed into the attic)
07/02/05 05:35 PM
Re: Hear I go again. Alum rear bumper

Dont wory about the Volvo bumper get a 2 inch x 4 inch aluminum channel or tube at least 48 inch but could be as much as 60 inches long it will fit perfect in the mounts. Use a thick gage though you do need the safety. The mounts are no big deal to take off. There's eleven spot welds on each one and a 3/8 bit cuts them right off. You'll have to bend down the top and bottom with a vice and tap some holes for the mounting bolts. I used 3 3/8 x 16 thead bots 3/4 inches long on each mount. Also while your under there you can pull off the tie down mounts. Which is good for about 5 more pounds. The rear of the car went up 1/2 inch with this project.

The 3/8 channel is about 10 buck for a stick and the bottom of the cover can use a 3/4 angle aluminum pieces about 4 feet long or just use zip ties like I did.

By the way I shortened the cover about 3 inch total.
This project cost zero dollars but the aluminum from a recycler should be about 5 to 10 dollars and they also may have some small channel for cheap also.


Polish
(Dr. Pilosh Haagenscodyberger)
07/02/05 05:40 PM
Re: Hear I go again. Alum rear bumper

Well that last post kind of confused me but once I get the bumper off I am sure it will make more sense. I actually just noticed that you shortened the bumper too. I don't know how I missed that. I can't wait to do this project. My car is going to have like a 10" fender gap.

curtis
(Space Blanket from NASA plumbed into the attic)
07/02/05 05:41 PM
Re: Hear I go again. Alum rear bumper

Yes I just took my calipers and pulled it parallel to the ground to scripe the line and then grabed the jig saw and cut straight up. You also have to cut the corner of the radius underneath and the top has to be cut the same way. Take your time one fause move and the cover is shot. I had the cover on and off about 25 times or more.

I've had a lot of experiance doing aicraft windows, sheetmetal, porting heads and lexan. Its not hard but just be carefull.


Polish
(Dr. Pilosh Haagenscodyberger)
07/02/05 06:03 PM
Re: Hear I go again. Alum rear bumper

Sounds good Curtis, I may have to PM you for some more details whenever I start this project. This is a really big help so far though.

4orced4door
(Out Standing)
07/02/05 06:09 PM
Re: Hear I go again. Alum rear bumper

Nice work!

atc250r
(Senior Ricer)
07/02/05 06:27 PM
Re: Hear I go again. Alum rear bumper

Quote:

Simply put, that looks better than rear jdm bumpers. SICK.




Wait, is that a USDM bumper re-cut at the wheel well? That really is a great alternative to JDM bumpers.

John


**DONOTDELETE**
(Unregistered)
07/02/05 06:40 PM
Re: Hear I go again. Alum rear bumper

Weight savings of totally REMOVING the bumper bar is 50 pounds so I don't think this will save quite that much. Mine is totally gone with just the foam support to hold it up. I may redo it to try and save a few more pounds but I'm not sure it will be much more.

curtis
(Space Blanket from NASA plumbed into the attic)
07/02/05 06:45 PM
Re: Hear I go again. Alum rear bumper

I dropped 48 pounds with the tie dow brackets and the removal of foam and the replacement of the bumper. The foam by its self weight in at 7 pounds. The top picture shows the scale. Part of the weight was also the dirt debrib and rust scale that fell out.

**DONOTDELETE**
(Unregistered)
07/02/05 08:28 PM
Re: Hear I go again. Alum rear bumper

Nice work bro, I'm in the process of doing this with the front bumper. It's almost done but not quite. The rear will be next. To think I was the only one with this idea! Do you have anymore pics of that rear support off the car? Might save me and some others some time? You said you had to beat the sheet metal in on the sides? Is that correct? What did you use to cut the bumper cover because my dremel just isn't doing a very good job. It's a good thing I had a junk spare front cover. Looks as good as I thought it would! Excellent work bro!

curtis
(Space Blanket from NASA plumbed into the attic)
07/02/05 09:29 PM
Re: Hear I go again. Alum rear bumper

I posted all the photos I have. As for cutting I used a Jig saw but before I started I covered the both of the saw with about 10 layers of blue painters tape to keep the metal off the paint. I also used a vibator sander on a few spots and a hand file on a few others the jig saw does the best on urethane covers because it cuts and doesn't create the heat from friction that a rotary file or cut of wheel does. As for the beating the bottonm corners have a lip that sticks out. I started by hammering it flat with the body then went up a little higher on the point that sticks out and started hammering it in. This was something I didn't expect but shit happens. The bumper cover accually is a slight bit smaller just as is raps around the back so this had to be done. The biggest problem in cutting this was the trimming of the corners just below the lights due to the radius in the corner and due to the fact that the cover got smaller so I took off a blade width at a time.

I started by cutting the top then put it on then sarted trimming the corner radi's then beat in the corners and so on and so forth. when all of that was done I drilled the bottom two mounting holes in the cover and last cut the wheel wels. Before you guys start this project coat the heck out of the 10 mm bolts with WD-40 on the underside and where ever else because I had to drill out and retap a few.


**DONOTDELETE**
(Unregistered)
07/02/05 10:40 PM
Re: Hear I go again. Alum rear bumper

Ah yes the foam. Maybe I could drop a few more pounds if I get rid of it.

50 pounds metal
7 pounds foam
18 pounds ureathane/plastic bumper cover


curtis
(Space Blanket from NASA plumbed into the attic)
07/03/05 05:42 PM
Re: Hear I go again. Alum rear bumper

autobahntom just offered me some mudflaps but would take some work so I come up with a solution for the problem of gettting dirt and debris in the space that is left from cutting off the lip. I'm going to run a strip of wide masjking tape down the edge of the body next to the wheel well then reinstall everything and fill the crack with 3M windsheild urethane. After it cures I can slice it with a razor and call the project complete.

As for the red marker lights they won't fit anymore so I'm taking some of the scraps from the cover I had left over and cutting out some rectangles to fill the holes with and maybe find some small red led markers or just install the covers and not the lights. If you do the project you'll understand because the lights now have no place to resess into. When everything is finallized I'll post somemore pictures.


cheekychimp
(Director of Housing and Urban Development, and carbon/kevlar balls)
07/03/05 10:57 PM
Re: Hear I go again. Alum rear bumper

Curtis,
Were Tom's mudflaps OEM ones? PM me before you do anything.

Paul.


curtis
(Space Blanket from NASA plumbed into the attic)
08/18/06 07:17 PM
Re: Hear I go again. Alum rear bumper

Well sorry for pulling up old history but there's new members now and people are talking about sending there car to see Jenny Craig so here's the after effects of a year.....Zero problems, installed cheap little leds in the lights. I've been lazy and haven't filled in around where I cut around the wheels probably 5 pounds of dirt in there. I'm doing the same for our Hong Kong connection, so I'll paint, patch panel the dents in the corners and seal with urethane later this month. Thats it.
Pictures.. enjoy

PS zoom in on my tag everyone.













**DONOTDELETE**
(Unregistered)
08/18/06 07:19 PM
Re: Hear I go again. Alum rear bumper

Pics of the gap from cutting between bumper and chassis please!

curtis
(Space Blanket from NASA plumbed into the attic)
08/18/06 07:22 PM
Re: Hear I go again. Alum rear bumper

I guess your wanting the photos of the wheel well ????? To see the gap if so I'll post some tomorrow.

JNR
(5 star (English Professor) member Has extensive pop up picture book collection)
08/18/06 07:28 PM
Re: Hear I go again. Alum rear bumper

Wow, how did I miss this thread, lol...

Damn nice work and thanks for sharing. I had similar ideas of pulling the USDM bumper inward and glad to see it can be done and look good

*adds another thing to the list, ha ha*


lunchbox
(:ugh: face)
08/18/06 07:29 PM
Re: Hear I go again. Alum rear bumper

That looks really wierd. Not sure if I like it.

Very very clean and well executed though.


**DONOTDELETE**
(Unregistered)
08/18/06 08:36 PM
Re: Hear I go again. Alum rear bumper

Quote:

PS zoom in on my tag everyone.








Did anyone zoom in @ the tag


1941Galant
(Will fight mice for food)
08/18/06 08:43 PM
Re: Hear I go again. Alum rear bumper



**DONOTDELETE**
(Unregistered)
08/18/06 08:46 PM
Re: Hear I go again. Alum rear bumper

Calling out Blacksheep

**DONOTDELETE**
(Unregistered)
08/18/06 08:51 PM
Re: Hear I go again. Alum rear bumper

Quote:








How did you do those headlights?


curtis
(Space Blanket from NASA plumbed into the attic)
08/18/06 10:15 PM
Re: Hear I go again. Alum rear bumper

Man I build stuff. I look at stuff and think and think until my mind starts to explode then stuff like this happens. I try to make things as clean as possible and am totally anal during the process. My biggest thing when done if it looks out of place or not professional it goes away. Nothing better to be modified and people not know.


Just like the signal lights which are now headlights. I was out in the shop one day and had one of the lens and started looking and then a few weeks later I stayed over at school and milled out the edge pieces and went back over and sanded and run a file for about and hour and they fit. I did a wrire up about these a few years ago and also built Paul's and Hill's headlights and Paul's JDM fogs. Which I like better than any I've done.
There's other weird stuff on the car that no one has never noticed from all the pictures I've posted. I have an extra VR4 windshild wiper spoiler on the passenger side. Junkyard score. The wing on the decklid has been shifted back about and inch or so. And have a wind deflector under the nose. I was mowing at the airport one day and it was laying next to the road. Didn't have any clue what it cam off of but it was install the first day I had it. Keeps me from draging on curbs because I here it first. Also good for bumping laser beams at the track.


blacksheep
(Baraqsheep)
08/18/06 10:16 PM
Re: Hear I go again. Alum rear bumper

Funny, Curtis. Real funny!

curtis
(Space Blanket from NASA plumbed into the attic)
08/18/06 10:27 PM
Re: Hear I go again. Alum rear bumper

Sorry brother had to do it after the rice killer incident earlier. I know paybacks a bitch.

cheekychimp
(Director of Housing and Urban Development, and carbon/kevlar balls)
02/08/07 07:00 AM
Re: Hear I go again. Alum rear bumper

These are pictures of the inside of the bumper after it has been cut. Note the holes that could easily get filled with dust, water, dirt and other road debris. The lower part could be covered by fitting factory or aftermarket mud flaps, the upper hole will need to be filled with window weld, sealant, filler or some other material to seal off the space inside from the elements.



cbr900turbo
(Junior Member)
02/13/07 09:54 AM
Re: Hear I go again. Alum rear bumper

You can definitely fill the bumper holes with polyurethane glue which will adhere I know 3m sells some to fix stock bumpers when they are damaged, you could then sand it and it would look like new.


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