Not infrequently, buyers turn to us with a request to implement an individual aerodynamics project for their car, in other words, to develop and manufacture a body kit, bumper, bumper skirt or other parts for auto-tuning according to a picture or drawing. Turning to us, the client, as a rule, presents everything rather superficially and does not suspect what is behind this development, what a titanic amount of work is behind the finished part that a person would like to receive. It would seem that here is a drawing for you, you are specialists, take it and do it. The customer usually suspects that the production of a custom-made bumper will take a little longer than the one already in stock, and the most important and erroneous opinion is that a "custom-made" part will cost the same money as a similar one from our catalog. It's a delusion. The author of the material site ©

In order to comprehend the upcoming scope of work on an individual project, it is necessary to have an idea of ​​​​how the production of tuning parts in general takes place, which are already presented in the catalog on the site, at least in our example, while we draw your attention to the fact that the production process looks the same for everyone without exception auto tuning parts manufacturers. You place an order, let’s say for a bumper, having accepted the order, the manufacturer-seller takes from the warehouse a ready-made matrix, in the production language “equipment” or, in the philistine language, “form” for manufacturing the bumper you ordered, and in it prepares the product for you according to your order. The key here is that the manufacturer takes a ready-made form, so the production time for your order, as a rule, is on average within 2-3 days according to technical conditions and requirements due to manufacturing technology, and the cost of this bumper for you is exactly as much as stated on the seller's website on the day of the order. This cost is calculated by the manufacturer based on the cost of manufacturing the product itself. That is, as you can see, everything is simple, you made an order and, as buyers say, the supplier "cast" the bumper, quickly and "at a reasonable price." The author of the material site ©

Now, based on what we have read, let's consider how your individual order will be implemented, that is, let's assume the manufacture of a bumper for your car, which you did not find in our catalog. The design and shape of the future bumper are agreed with you, then we get to work. There are several ways to implement the project, consider the average. First of all, for the period of modeling work, we need a car similar to the one on which the bumper is modeled, if not for the entire time of work, then at least with a periodic visit to us for fitting. We solve this issue on our own and as a rule it is difficult to find a car for the modeling period, one of the options is to rent a car. Next, we purchase a used regular bumper from the "dismantling", on the basis of which the work will be performed. Having rented a car and purchased a regular bumper, a "modeller" is taken to work, who, with the help of special materials and ways begins to form, "bring out" appearance future bumper corresponding to the picture or picture you provided. Only this operation can take at least a week or two, depending on the complexity of the geometry. When the bumper model is ready, the "matrix" is taken to work, he begins to make a transitional, in other words, an intermediate matrix (form) from the received master model. Resin, glass mat and glass mat are applied in several layers with keeping the drying periods of each layer. The term for this operation takes another week. When the transition matrix is ​​ready, the first test product, i.e. the bumper variant, is molded in it. This primary bumper undergoes a thorough fitting and fitting on the car, geometry violations that may have been made during modeling are brought and corrected, all dimensions and distances are checked, as well as the mirroring of the right and left sides of the bumper. This operation may take up to a week. Then the finalized version of the bumper undergoes surface refinement, which is finished with polyester putty, the surface, as they say, is brought to zero, all flaws are eliminated. The term of this operation is 3-7 days. From the finished and final model, they begin to remove the matrix, that is, to prepare the final (finish) form. Resin and matrix glass mat are applied to the bumper while maintaining all the terms and periods of drying of each of the layers. Layers on average can be from 5 to 15, depending on how long the matrix (mold) is planned for. The duration of this operation is 1-1.5 weeks. And only then, when the matrix is ​​ready, a finished bumper is produced according to your project, it will take about 2-3 days to make it. The author of the material site

As you can see, the process of implementing your project, for just one bumper, takes a lot of time, requires serious material investments, this is a car rental and purchase standard bumper, a huge consumption of materials for modeling, as well as payment for the work of a modeller, matrix worker, moulder. As a result, the period is about two months, and the material costs are approximately equal to the cost of five finished bumpers made from this matrix. Therefore, only being clearly aware of the entire scope of work, you need to make a decision on the implementation of the idea and ordering one or another part individually. Usually it is less expensive and many times faster to find something ready-made among the many offers from various suppliers, thereby not overpaying and saving your time. The author of the material site ©

The unconditionally presented concept of modeling your project is partly superficial, the main points of the manufacturing process are affected without going deep into the technology, but general principles sure clear and understandable. In conclusion, we can consider several similar projects that we have already implemented earlier.

Production of bumpers - replacement of damaged or tuning a new one

Most motorists sooner or later think about buying a ready-made bumper in Moscow or purchasing a custom-made one.

The bumper, being an element of the external decor of a car, can be an element of body kit tuning. And by replacing the stock bumper with the original one, you will give the car your style. And for racing fans, there are options for aerodynamic bumpers that improve the car's streamlining, handling and maneuverability.

The increase in the number of cars inevitably led to an increase in the number of accidents. The most frequently damaged body part is the bumper, which is designed to absorb the kinetic energy of an impact in an accident. The imperfections of the roadway and debris also negatively affect the condition of the bumpers - chips, scratches, cracks appear.

Bumper material: plastic or fiberglass?

The main materials from which bumpers are made are as Russian production, and for foreign cars are plastic and fiberglass. The details of them differ in their low cost, plasticity and maintainability, lightness and strength, lack of corrosion, resistance to chemical and ultraviolet effects. The difference is only in the production technology of bumpers from these materials.

So, fiberglass is several layers of fiberglass, alternately impregnated with special resins. And the composition of the plastic is polypropylene, rubber and a number of stabilizers and dyes.

The process of creating a bumper goes through several stages

The bumper design can either be developed individually according to drawings or photographs provided by the customer, or be universal, standard for all cars of this model.

The very model of the future bumper is molded from sculptural plasticine. Your wishes will be taken into account, and possible changes in the design will be introduced at this stage. Then computer graphics come into play. The bumper model is entered into the computer with the help of engineering programs. 3D scanning fixes the coordinates of certain points on the car body. A computer model of the bumper is superimposed on the data obtained from a 3D scanner using special graphic programs. Based on the data obtained, a matrix or technological equipment is formed - a mirror image of the future part.

Bumper production technology

The production of technological equipment or a bumper matrix is ​​a laborious and responsible process. After all, the quality of the part directly depends on the form according to which the part is made. The computer model of technological equipment is absolutely accurately reproduced on milling equipment with numerical control. On 3D machines, it is possible to manufacture matrices with complex geometric shapes. According to a given program, 3D milling is carried out along certain coordinates in several planes. This method of manufacturing a matrix from metal or composite materials is suitable for manufacturing a large number of bumpers.

The production of a custom-made bumper is more jewelry and thoughtful work. First, a rough or intermediate tooling is created. Several layers of fiberglass impregnated with a special resin are applied to the bumper model. After hardening, grinding and coating the resulting form with a protective and decorative gelcoat composition, which prevents the formation of “shells” and microcracks, a bumper prototype is created in it. After manufacturing, the prototype is carefully tried on the car. The dimensions, symmetry and general geometry of the part are checked, and possible minor flaws are eliminated.

The final bumper is then treated with putty and sanded to serve as a model for the finishing matrix, which is treated with a wax polish to ease the removal of the part and a gel coat. This model also covered with layers of reinforcing fiberglass impregnated with special resins. Layers can be from 3 to 8-12, depending on the required thickness of the part. To obtain the necessary plasticity and hardness of the material during the molding process, it is necessary to withstand a certain time of thickening and hardening of the fiberglass layers. The resulting bumper is removed from the tooling. For geometrically complex options several matrices are made, the details of which are then reduced to a single bumper.

The production of plastic bumpers is carried out by injection molding machines. Special granules containing polypropylene, rubber, ultraviolet and heat stabilizers undergo heat treatment and are thoroughly dried. Then they are heated by injection molding machines to a temperature of over 200 degrees Celsius. The resulting composition is poured under pressure into technological equipment, where it takes finished forms.

The resulting bumpers are puttied, polished, primed and painted with enamels for plastic surfaces.

These are just a couple of ways to make a bumper for a car. A custom-made bumper can be produced, including by vacuum infusion or contact molding, as well as by pressing or spraying.

Qualitatively produced and original bumper will give your car a unique image. Our craftsmen will not only make an original custom-made or universal bumper for you, but they will also be able to install it.

Undoubtedly, bumper tuning has always been and remains a hallmark unusual car. Never will a regular solution provide so many opportunities to express the individuality of the owner and create a truly fresh LOOK for the car body. Automotive market trends and technology are moving forward, and with them, and. Today, a wide selection of front bumpers on Porsche cars, Mercedes, BMW, Toyota, Lexus and many other brands have made the range of top tuning the most attractive for the most demanding customers. Unusual and strict, low and high, with daytime running lights and air intake gills - the front bumpers have become the main activator in the direction external tuning cars and truly occupy an honorable first place in the ranking of our catalog.

Buy front tuning the bumper or the entire body kit is a matter of approach. Some novice tuners start with a replacement front bumper and gradually bring the car to perfection by combining elements and creating a unique image. This method distinguishes buyers with a vivid imagination and bold, non-standard solutions in terms of the appearance of a car. The latter, as a rule, prefer brands and are ready to rely on the opinion of professionals who have carefully created the image of a car body kit in a single concept and take into account the specifics of a particular design.

Shop Top Tuning is ready to offer you the maximum selection of front bumpers from the extensive catalog on our website. Select required car and we hope you find the look you've been looking for!

Every person wants to express their individuality. Someone buys clothes, jewelry or collects stamps, and motorists upgrade cars in every possible way. In this case, tuning is the most common way to transform a car. notice new engine maybe a small number of people, but the updated building catches the eye immediately.

Ordering a bumper or other part in a store is quite expensive, so it makes sense to do body kit on a car with your own hands. With a minimum set of knowledge, you can get a lot of benefits, including:

• Significant cost savings compared to a custom body kit
• The ability to create a unique body kit for the car
• The work is done independently, which means that with due effort it will be done in good faith
• Acquisition of real useful skills

How to do interior tuning we tell in this article. About 3D virtual tuning -.

Preparatory stage

Before you make a body kit, you must dismantle the old one. Depending on the car, body kits can be attached in different ways. For example, the "Japanese" have them glued to double-sided tape and self-tapping screws. Having unscrewed all the bolts, it is required to remove the remnants of adhesive tape. There is an option when the caps are used as fasteners.

With a used car, it can be a little more difficult, because perhaps the previous owner was also a fan of experimenting and secured the body kit with sealant. In order to get rid of its traces, you will have to use professional polishing of the body.

Regardless of the mounting technology, it is recommended to use a garage with a hole or a jack for such work. After detaching the parts, corrosion may be found in the place where the body kit was located. Remove it with a grinder.

Body kit manufacturing

In order to understand how to make body kits for a car, you need to decide what you will make it from. The best material in terms of price / quality ratio is consideredstyrofoam. Before applying it, carefully glue the place of application with adhesive tape.polystyrene foam.

Having finished the preparatory work, we cut it into cubes and stick it where the new body kit will flaunt. The size of the pieces depends on the dimensions of the body kit. Remember to pre-treat the surface that will be adjacent to the machine. Glue the pieces with macroflex . It must be applied in a thin layer. We recommend dicingpolystyrene foamwith a margin. The structure itself is glued in various ways, including:

• High quality double sided tape. Otherwise, the body kit on the car with your own hands will disappear after meeting with puddles
• Sealant, but if you want to remove the body kit again, it can damage the paint

The result obtained is the foundation. The next step is to givepolystyrene foamdesired shape. For this stage, you will need an electric knife, as well as a large skin. When working, it is advisable to pay attention to the following tips:

• Glue cut blocks only on the car
• Your task is to give the piecespolystyrene foamcar body shape. This is done in order to ensure a snug fit of the material to the car body. This solution will reduce the number of cracks and further problems in the following stages.
• It is recommended to lay out the blocks as if brick laying is taking place. Lay them out block by block and meticulously adjust to the desired shape. Of course, you will spend about half an hour on this, but in the future you will understand that the time was not wasted in vain.
• Don't Forget the Minimum Security Precautions

After working with polystyrene foama lot of dirt remains, so there is a possibility that the material can get into the car's air duct. Don't forget to vacuum it.

If you want to make the bumper skirt even, dismantle it and put it on the table. Thus, the work will move faster and better.

Shaping

The shaping of the body is carried out with a large sandpaper of 40 millimeters. Wrapping it on a stick, you get an excellent file. The electric knife is good remedy to give a rough outline. Use the "magpie" to give a rough shape. Having reached the limit of half a millimeter to the desired result, go to 80 mm sandpaper.

Regardless of which part of the body kit you make, you need to make every effort to achieve complete symmetry. Before proceeding to the next step, carefully check that all parts of the body kit fit snugly against the body. This work is the most difficult in the question of how to make a body kit with your own hands. Use 40mm sandpaper for adjustments.

Coating

Cover the resulting body kit with a single layer of fiberglass epoxy, which must be cut into small pieces. Apply resin first, followed by fiberglass. Glue the entire body kit. In some places dripping drops of resin are formed. It is recommended to remove them after the resin has cured. At this stage, it will not be superfluous to follow a few tips:

• Stock up on pieces of fiberglass
• To obtain a normal density, lay the fiberglass with an overlap
• Small pieces of fiberglass are easier to glue

A durable layer is achieved by pressing down on the fiberglass with a brush dipped in resin. Run it from the middle to the edges until the material is completely saturated with resin. Avoid the formation of air bubbles.

After drying, start applying a layer of coarse putty. main problems at this stage will be applying an even layer. This process is necessary to remove all irregularities and flaws. After that, walk sandpaper to remove problem areas. For getting best result you will have to repeat the process several times. Small indentations are removed with putty.

When everything is dry, carefully review the design. Make sure that symmetry is observed and feel free to proceed to the next step on how to make a do-it-yourself body kit. Now you are required to:

• Delete received element from bumper
• Detach the original skirts and wipe them well
• Make a template for the outline of the skirt from the side that is in contact with the fiberglass bumper. Apply multiple layers of fiberglass to keep the template strong
• Carefully unfasten the workpiece from the bumper
• Clear the received part frompolystyrene foam. Do this gradually as the layout loses its rigidity, so treat it with fiberglass and then apply a layer of resin
• Detach the side skirt templates to get the mounting base
• Make a few cuts on the fastening bar, so that later you can connect it to the skirt. Similar undercuts are made on the skirt

Fastening parts

Take a blank made according to a template from the factory bumper mount. Attach it to your skirt with fiberglass and resin. As soon as the structure hardens, fasten the skirt to its regular places using factory bolts.

There is a high probability that the part will sit badly. There may be cracks and discrepancies, but this problem is solvable.

In this case, masking tape and elastic putty will help you, which must be applied along the line of contact between the skirt and the bumper. We are waiting for the solidification of the material. After that, we dismantle the skirt. It will be clearly visible influxes. Remove them carefully.

Now you should increase the flow in the lower part of the skirt, located on the side of the wheel. To do this, take a piece of cardboard. Cut out the desired template and glue it with tape. In order for the cardboard not to lose its shape, strengthen it with two glazing beads . To complete the work on the body kit on the car with your own hands, there are a few steps left:

• Apply multiple coats of fiberglass resin to stiffen the structure
• After the resin, we process the part with putty and level the surface with sandpaper
• You will most likely have to apply several layers of putty to get a smooth surface.
• Try the item on the car

When you have done the whole front of work, you need to pay attention to one detail. When the wheels of the car are turned sideways, a gap in the skirt will be visible, so it is necessary to make protective corners, which are made using elastic putty, cardboard and masking tape by analogy with a stiffener. Now you know how to make body kits for a car.