95 Audi 2.0 Sport Refurb...

Newbie Joined: Jan 01, 2007 Posts: 19

I've moved this from another forum to here as it is a full project revamp that has taken nearly a year now to get her to this stage. I will start to get the photos that I've taken and post them here from start to finish, but some of them will be out of order... Wink

There's refurbisment of wheels, dissapointment with Rieger Bumpers, Headlamp fiddles, simple body repairs... I hope it will be interesting if nothing else... Very Happy

Here we are at the present

Been tarting up my old warhorse that I bought last year thought you might like to see hows shes coming along...

Here she is with a Cabriolet bumper that I put on...

The Fog's and indicators are all of Porche 933 origin and were used on the Audi RS2's and final edition Cab's, the fog's alone are £130 each OEM and second hand ones are like hens teeth and still nearly as expensive or more to boot. So I've decided to fabricate a couple of 'blanks' set back in about 10mm and a fog light with a stainless steel fin running horizontally across the lenght of the original recess...

The blanks are now done and dusted, just need some tidying up with a bit of filler here and there, primed and painted then will make some moulds and redo for perfect fit…

They're in one piece and will only need a single fixing when finished…

As you can see they are moulded directly from the bumper so they are nice and snug…

The edge will need to be shaped to a curve to match the bumper, haven’t decided yet wether to leave them blank or to have some recessed day lights, or single spot, or a single spot with air inlet or just air inlet… Wink

Will eventually get them painted same as bumper, though did think of doing them with Chrome Effect Paint for some bling… (No only kidding…)

Well got some enthusiasm together and started on preparing the blanks ready for painting, one anyway…

Here I’ve already blocked the face of the blank with some 180 and tided up the rear with a belt sander. Because the outer face was laid up last, as a consequence there was a small amount of shrinkage, which created a shallow dip to the face, so it needed refacing…

It also needed a small amount of sanding to the edges to create a curved edge to match the bumper, here you can see the difference between the basic blank edge & the one sanded…

After the face was marked to show the amount to be sanded to form the curved edge, hopefully matching the existing.

As you can see the edge did need a little repair / reshaping after sanding, but nothing major…

There’s quite abit of faffing about with this type of thing especially as it is all done by eye…

Another trial fit… D’oh!

When I was happy with it , it was time to get it primed, then you can see any bits that need reshaping. You will need to give it a good blow over to remove the dust and spirit wipe it before giving it a quick going over with Grip4 (Adhesion promoter in a aerosol…)

Followed by a bit of the grey stuff…

Any minor pin holing can be filled with the primer…

I’m going to let it air dry for a couple of days before blocking it down again and re-priming.

Then I will block it down again, give it a gash coat of 2K solid and then time to make the final mould…

Site Moderator Joined: Aug 11, 2008 Posts: 1652

could have just asked for your other post to be moved (i've removed the older post to keep any feedback in the one place) lol Wink

good job though, canna wait to see how it progresses Very Happy

Newbie Joined: Jan 01, 2007 Posts: 19

Put it down to old age... Wink

Archie...

Newbie Joined: Jan 01, 2007 Posts: 19

Little update... Wink

Been a bit busy with one thing and another lately, but finally got the two of them ready for paint.

Blanks are given a gash coat here ( 3 coats of 2K Solid Audi Brilliant Blue ) to check for defects in the finish…

Checking fit here to make sure the gap & edge curve is even…

Both blanks are nearly up to OEM finish, they will have a final rub down again to ensure they're spot on, followed by the final refinish of base & clear…

Now will be able to get the bumper preped & painted in Audi LZ5U Indigo Blue Mica and properly fixed... Nearly done and dusted... Very Happy

When finished will make the final moulds from these two ‘prototype’ blanks… Then will be able to fashion any number of permutations

Posted: Wed Nov 03, 2010 4:13 am

I love this DIY bodywork stuff!

How did you go about making the blanks?
You said you moulded them directly from the bumper's recess. From the photo's it looks like fibreglass, how did you mould fibreglass without it sticking to the bumper etc?

It'll be interesting to see your final interpretation of the bumper...