Intro: Foam Rebuild of Bumper
Materials need for this type of mold with expanding foam, can work with any vehicle. This project was inspired by drawings
-body filler file
-sandpaper 80 grit or coarse
-hot glue gun and glue sticks
-large enough piece of fabric to cover entire form
-not needed super 77 spray adhesive
-1/4" plywood for platform and output of existing car bumper contours
Step 1: Cardboard Structure
I had made several drawing beforehand to create the idea and look I was going for. Based my cardboard construction on the drawing and the body lines
Constructed a cardboard form on a piece of wood to the desired idea of the bumper, that also fit to the outer of the existing bumper from my car at the time
I used the hot glue gun to get the cardboard to stay in place
Step 3: Adding Expanding Foam to the Cardboard Structure
With an assortment of body filler files and sandpaper you can achieve the look you want with the curves and body lines you desire .
I used the expanding foam in-between the cardboard bits at a time then carved them the next day to ensure a full cure from the expanding foam since laying up in bigger sections
depending on how much of an area you fill will depend on time of cure, keeping in mind the working temp for the matter in the can.
shave off and use marker to create ideal body lines
Also sharp knives or exact blades were used in the process of cutting the foam
Step 4: Sculpting
Body filler files and rasps sandpaper all made this possible.
The use of a sharpie was great to draw in body lines to follow when carving out
Plenty of carving and refilling with expanding foam
Step 5: Cover for Fibreglass
Cover with tape or latex paint with a roller then you can proceed with laying up your fibreglass
I used 3M tape for my project
As a first coat used a thick fleecy fabric to get a good even layer and to get body lines glued in certain spots
for glueing the fabric to the form I used 3M supper 77 spray adhesive
At this point after laying up my Fiberglas I attached the form to a plastic bumper half with screws and fiberglas strand from a can, sanded it up and layer another layer of glued fabric to cover the whole bumper on the car
Adding a bumper from the car your making is allot easier than trying to make sections around headlights, grills and tabs to attach to the fenders. I picked up a broken bumper from the scrap yard for 30 bucks
Step 6: Sanding and Getting Ready for Final
The use of short strand fibreglass putty and some sanding I was able to get closer to my goal
Additional expanding foam was needed for a section
Unfortunately I had to get rid of the car so never got past the point of the end of this instructable. Hope this inspired others to follow an idea !