sixshooter

iTrader: (12)

The bumper cover does not seal to the plastic bumper support. I had to cram upholstery foam in the gaps. I also opened up the top of the bumper mouth in the bumper cover and eventually in the plastic bumper support right above the bumper mouth to allow more air to come through. I sealed it so that additional air would come up behind the plastic bumper support and over the metal cross beam and go to the top of the radiator. Lots of additional air flow to be found there, just seal it up good.

Engi-ninja

The Amazon fairy brought it :-) Probably not the most cost effective, but the flat sheets were much easier to work with than when it comes rolled up.

Excellent, very good to know, thanks! I didn't think that much would escape around the crash bar. I'll work on sealing that up too.

Gee Emm

CAD rocks! You did a better job than I, but I have to redo some and will try harder LOL! Your work has inspired me to extract the digit and get on with it, I may even re-do the whole bloody lot. Have a cat!!

I like your clamping/bending tools, did you use a heatgun to soften the plastic to bend it?

Engi-ninja

Thanks dude! There was definitely a learning curve, but it seems to be working well, so I'm happy with the results! Yes, I used a heat gun to heat the ABS. I would clamp it between the 2 sheets of subflooring, with the bend line right at the edge. Then I'd heat it up and bend it with another piece of wood. One interesting thing that I found was, if I didn't heat it enough before I bent it, it would actually straighten back out if I heated it up again. This was particularly annoying when I had several bends near each other, as the previous bend would start undoing itself as I was heating the adjacent area. Then I found that if I applied heat long enough, it would stay bent even when I heated it up again.

Gee Emm

Thanks for those tips, I figured you would had to use heat but knowing about it 'unbending', and how to prevent it is really useful!