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Posted by: root Dec 12 2004, 09:20 AM

I just finished all the major work installing a front glass bumper from 'rennsport'
on my '72. Next is the rear. I'm going to attempt to post some pics.
Here goes.....

Posted by: scott thacher Dec 12 2004, 09:22 AM

my first

Posted by: spare time toys Dec 12 2004, 09:22 AM

wow its the stealth bumper I did not know those were for sale yet

Posted by: root Dec 12 2004, 09:23 AM

Hey, what did I do wrong?

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Posted by: root Dec 12 2004, 09:24 AM

checking the fit

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Posted by: root Dec 12 2004, 09:26 AM

bracket I added for bolting on permanent - 'till I crash!

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Posted by: root Dec 12 2004, 09:27 AM

I also added a knife edge aligning plate on each side to the inside top edge.

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Posted by: root Dec 12 2004, 09:28 AM

welded in the headlight web

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Posted by: root Dec 12 2004, 09:30 AM

closeup up of welded web with bondo over the weld

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Posted by: root Dec 12 2004, 09:32 AM

major work complete, with 'pilot' driving lights from 'camp914'

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Posted by: sgomes Dec 12 2004, 11:42 AM

Outstanding job!!!

Posted by: neo914-6 Dec 12 2004, 11:50 AM

Why bond it in? Won't it be a PITA to repair?
Felix

Posted by: root Dec 12 2004, 11:59 AM

Here's a corner shot. As far as repair goes. Sure it can be a pain if you look it
glass work that way. I like working with just about all materials, it's fun for me!
I just wanted to see how good a job I could do glassing the whole thing. If
I crack it or crash it I'll deal with it. I cutout the bumper below the driving lights
I can access them, what else do I do I need access to behind the bumper?

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Posted by: rdauenhauer Dec 12 2004, 02:09 PM

Pretty clean
Where are your horns?

Posted by: rhodyguy Dec 12 2004, 04:34 PM

nice work. don't get your fingers caught in the headlights.

kevin

Posted by: root Dec 12 2004, 07:49 PM

I never really thought about getting my fingers caught in my headlights.
Do you suppose that was the reason for the original design having rubber
mounted webs in the front of the lights? I guess it could pinch you pretty bad.
Wonder if my old reflex's are fast enough? I got an idea!

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Posted by: rhodyguy Dec 12 2004, 08:22 PM

HEY!!! i think i know those wheels.

kevin

Posted by: michel richard Dec 12 2004, 09:24 PM

The thing with the eyelashes was for any kind of material getting caught in there, fingers, or other stuff.

Michel Richard

Posted by: root Dec 12 2004, 09:58 PM

Kevin, I really like the wheels. I'm gonna miss them when I go to five lug.
Think maybe I'll stick with four lug, saw them in half, and weld in a spacer.

Posted by: root Feb 12 2005, 11:10 AM

fibermorphing flares

Tapped on sizing up!

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Posted by: root Feb 12 2005, 11:12 AM

Marked for cutting -

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Posted by: root Feb 12 2005, 11:13 AM

sheet metal screws holding it on prior to resin and fiber -

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Posted by: root Feb 12 2005, 11:14 AM

overview before I begin the permanent install -

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Posted by: Air_Cooled_Nut Feb 12 2005, 11:42 AM

I'm envious of your skills. She looks great so far!

Posted by: root Feb 12 2005, 07:38 PM

left flare-in-process....
2 lines: outer line is outer edge of flare, inner line is cut line.
I left the two bottom strips as they have the original fender well
support braces.

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Posted by: root Feb 12 2005, 07:40 PM

15 sheet metal screws to register the flare alignment when the fiber and resin go on.

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Posted by: root Feb 12 2005, 07:41 PM

left-side

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Posted by: root Feb 12 2005, 07:42 PM

drilling a starter hole for the nibbler

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Posted by: root Feb 12 2005, 07:43 PM

nibble time

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Posted by: root Feb 12 2005, 07:45 PM

ready to grind off the paint around the edge
note the 2 bottom strips for support

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Posted by: root Feb 12 2005, 07:46 PM

ground down to the metal

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Posted by: root Feb 12 2005, 07:48 PM

resin - fiber - screws holding it 'till tomorrow after resin cures!

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Posted by: BahnBrenner914 Feb 13 2005, 02:13 AM

did you have to modify that front bumper much? I got one and it is a really bad fit. you have any suggestions?

Posted by: neo914-6 Feb 13 2005, 11:10 AM

Dan,

Did you need to flare out the metal to match the f/g lip? Mine (Bills ex) were to match the HPH flares and they weren't bonded....

Are you going to add f/g mat/cloth on the inside?

Nice work and pics

Posted by: root Feb 13 2005, 09:33 PM

QUOTE

Did you need to flare out the metal to match the f/g lip? Mine (Bills ex) were to match the HPH flares and they weren't bonded....

Are you going to add f/g mat/cloth on the inside?

No I didn't bend the metal at the cutout edge to match the flare. The flares have about 2.5" of flat flange like area that I was able to bond to.
1. Painted both surfaces with fiber resin
2. layed down short pieces of cloth between the screw holes (otherwise the screwss twist up the cloth into a choatic ball of fiber).
3. layed down long 12" strips of cloth along the outer edge (away from the screws)
4. There's a small 'V' notch along the inside where the metal and f/g meet I have filled
that with 'cat hair' to provide more support. I'll under coat the seam at the end to resist moisture.

QUOTE
did you have to modify that front bumper much? I got one and it is a really bad fit. you have any suggestions?

The right front was damaged by PO years ago. I had to pull that out about 1/4" to get it to reach the end of the bumper (hydraulic jack, chains and PITA )
Otherwise the fit was O.K. Where's yours fitting poorly??
In general, you can make fiberglass fit where ever you like.
It's Just :
1. Messy
2. A job that requires iterative resin/cloth layups (roughing the surface) each step
3. Use of sculpting foam and/or wood pieces for curbing and bridging for small gaps if you dare!

Here's a value added benefit -
if you get enough foam and wood it maybe a floatable teener.

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Posted by: root Feb 13 2005, 09:36 PM

The above pic was taken after I coarse feathered the resin and fiber edges.
Next I fill the screw holes with putty and surfacce putty the edges and refeather.

Posted by: SirAndy Feb 13 2005, 09:45 PM

and when it's all done, she will look like this:

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Posted by: SirAndy Feb 13 2005, 09:46 PM

rear also molded in ...

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Posted by: SirAndy Feb 13 2005, 09:48 PM

btw. i also molded in the rockers ...

looks great, keep up the good work!
Andy

Posted by: Aaron Cox Feb 13 2005, 09:48 PM

AAHHNDY

i like the look of the glassed in ducky.....

Posted by: root Feb 13 2005, 09:59 PM

SirAndy, I got a pic of yours and a couple others on my desktop!
To keep me motivated....

Posted by: JohnB Feb 14 2005, 11:13 AM

Nice work, the good weather we had the last few week ends must be helpful when you have to work outside here in the DC area. When you gonna put that thing back on the road?

Posted by: JmuRiz Feb 14 2005, 11:57 AM

Looks good, BTW where in Sterling are you, I'm in the woodstone area. Nice to see other local 914s that I don't know of. Maybe this car will be ready for Kerry's 914 picnic in Sept!

Posted by: root Feb 14 2005, 11:57 AM

Yep! The weather is one of the main obstacles in control of the project.
Basically it goes like this;

Project Obstacle Priority List

1. Wife
2. Coaching Hockey
3. Weather
4. $$,$$$

Maybe ready for the road in July!

Posted by: root Feb 14 2005, 12:03 PM

Sterling is my R&D business location- just North of Dulles Airport 504 Shaw Road
....but I live in Chantilly. We work on cars (2 son's and I) at home in Chantilly as well as
in the machine shop at work in Sterling.

Posted by: JmuRiz Feb 14 2005, 01:50 PM

Ok, I know that area, been past there many a time, cutting through from Herndon parkway to 28, before the Old Ox/28 exit was done. Sometimes I use that bit as a test loop for my car, herndon parkway and sterling blvd.

Posted by: scooter311 Feb 14 2005, 02:11 PM

Hey root looks great! Are you doing the fronts as well (maybe I missed that somewhere) and what color are you painting it?

Hey Andy I your car

Posted by: root Feb 14 2005, 03:33 PM

Yep! Soon as I finish the rears, then I'll do the fronts.
Absolutely no idea about color..
I'm really becoming fond of primer grey
Wonder what clear coat would look like on top of primer?

Posted by: Scott Schroeder Feb 14 2005, 03:57 PM

Hi Root -
Mine was done the same way, except for the head light eye brows.....

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Posted by: Scott Schroeder Feb 14 2005, 04:02 PM

... the funny part is that I cant wait until I have the time to bust them off with a hammer and go back to the normal fiberglass GT bumpers. The PO put them on my car.

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Posted by: root Feb 14 2005, 04:18 PM

Yea. My plan is to keep like this 'till I smash into something.
Then maybe re-fibermorph into something different.
Just hope the bumper lasts 'till I get the fenders and rockers on.
I'm always racing it in and out of the garage for sanding, only time I get to
drive

Posted by: root Feb 14 2005, 04:21 PM

Scott, is the the right front corner of a red Austin Healey in the bottom of the photo???

Posted by: Scott Schroeder Feb 14 2005, 04:32 PM

Yep - a 3000 BJ-8.

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Posted by: root Feb 14 2005, 04:52 PM

Scott- me and my 3rd restoration job, '58 Healey 100-6. I really miss that car.
Yea that's me in the pic, not my flat chested girl friend.

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Posted by: root Mar 13 2005, 07:24 PM

The sun came out this weekend and I got most of the FG flare work complete.
Next task is to mold in the rockers and rear bumper!

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Posted by: root Mar 13 2005, 07:26 PM

I need some wheel and rubber to fill those flares up!

Posted by: Aaron Cox Mar 13 2005, 08:03 PM

QUOTE (root @ Mar 13 2005, 06:26 PM)
I need some wheel and rubber to fill those flares up!

say it with me:

hello five lug

Posted by: root Mar 27 2005, 03:59 PM

Got some more progress done on the 916 fibermorphing....

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Posted by: root Mar 27 2005, 04:01 PM

REALLY NEED MORE WHEEL AND RUBBER NOW!

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Posted by: Aaron Cox Mar 27 2005, 04:03 PM

need mo rubba.....lower the rear...and lose the monza

Posted by: SirAndy Mar 27 2005, 04:04 PM

QUOTE (root @ Mar 27 2005, 01:59 PM)
Got some more progress done on the 916 fibermorphing....

hey, that exhaust cutout is crooked!

just like mine ...
Andy

Posted by: root Mar 27 2005, 04:08 PM

Actually the Monza is bent and the cut-out is crooked

Posted by: root Mar 27 2005, 04:12 PM

Looks like it stopped raining for a couple minutes, back to bondo
shaping for me!

Posted by: Andyrew Mar 27 2005, 04:19 PM

Lookin good! Gona be doin that myself pretty soon...

Posted by: jgiroux67 Mar 27 2005, 06:52 PM

That lookes exactly like my car. Gt flares, 916 front and rear bumpers, everything molded together, primer gray. The only thing different is I just finished the 5 lug conversion and havent cut out anything from the rear bumper yet. I think I might go with the Triad exhaust but I have to save up some money first, anyone want to buy a Bursch exhaust?

Posted by: jgiroux67 Mar 27 2005, 06:55 PM

Oh ya, can you show a picture (you too Andy) of what you did with the gap between the front hood and front bumper? I cant seem to get that right yet.

Posted by: SirAndy Mar 27 2005, 09:55 PM

i don't have any real closeups, let me know what exactly you want to look at an i'll take a pic tomorrow ...

Andy

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Posted by: jgiroux67 Mar 27 2005, 10:19 PM

Something like this, I want to see the hood gap.

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Posted by: jgiroux67 Mar 27 2005, 10:20 PM

another, I dont know why that is so bad quality

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Posted by: Aaron Cox Mar 27 2005, 10:25 PM

nice shoes

Posted by: jgiroux67 Mar 27 2005, 10:27 PM

Adidas tuscany gt

Posted by: Scott Schroeder Mar 28 2005, 12:45 AM

...

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Posted by: Andyrew Mar 28 2005, 01:38 AM

Make it tight with fiberglass, and grind it down to 1/4 in. gap all the way around...

Put a little bondo to hold it, and paint....

Thats what I would do.....

Then again... I've never worked with fiberglass (this week I might do it... IF not then sunday.. lol

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