Danny Humphreys

I have some experience working with CF making some smaller parts and repairs to race car bodies, but this will be my biggest undertaking by far. A little background. My blue 78 has a Jacquemond front cover on it. Several years ago it got stuffed into the guardrail and was repaired. The shop did a good job but used a ton of filler and it's heavy as hell now. Way more than a factory cover, prob 25-30 lbs easy. I'm getting this car put back together and decided to address the front cover. So follow along as I put my motto to the test. "There's nothing I can screw up that somebody else can't fix"
So first thing I did was look at the cover to see how hard was it going to be to make a mold and would it have to be more than one piece? After studying it I decide that by making some modifications to it I would be able to make a one piece mold and simplify things.
The first picture is the cover as it was. The two openings on either side complicated matters, so I decided to do away with them. Jacquemond makes a covers without them, so I was able to see what it would look like. I think it makes it look more shark like anyways.



2nd pic is without them and the holes glassed up.

Danny Humphreys

In addition to those changes I also decided that I wanted to add a chin spoiler and splitter. This actually made the whole thing much easier from a mold standpoint. So I started out by screwing the cover to a piece of plywood and constructing a spoiler out of aluminum.

Danny Humphreys

Then I covered it with fiberglass.






Now it's off to the body shop for them to finish it out and make it perfect so I can pull a mold from it.

Not bad for a leisurely Sunday afternoon, and morning and evening!

BTW This will be a wet layup vacuum bagged piece.

OTR18WHEELER

NICE!, I have wondered why this mod has not been done. , or at least documented.
A one piece mod.
(watching closely)

M. Requin

Very interesting indeed! It would be great to see pics after the body shop has finished fairing it out.

marks gt

That is the only aftermarket bumper cover that looks like it should be on a 928

Mrmerlin

nice work thanks for sharing your ideas,
I hope this turns out to your liking

andy-gts

I always wanted a bumper cover like that one !!! very nice

Fabio421

I could have saved you some trouble. I've already got a mold for a similar front cover. In fact, I've got molds for a rear cover, side skirts, rear flares, and the entire front widened fenders with stock lights. Where are you located?

Please keep this thread updated. I'm looking forward to see how it turns out.

Danny Humphreys

Just saw this. I'm just south of Dallas Tx. Where r u?

Still waiting on body shop. Made a visit Friday and told them I would pick it up next Friday finished or not

1989porsche928

you could cover the original bumper with wax and just lay the carbon fiber over it

waynestrutt

Why would you do that?

Speedtoys

That wont be the same sized bumper..in the end.

Because it's OUTSIDE the lines of the OEM unit.

Make a mold, then you make things from them.

James Bailey

http://www.smeenandpaully.com/video/...glass-mould.ht

This is a pretty good video...
- Making A Fibreglass Mould - SmeenandPaully



http://www.smeenandpaully.com/video/...glass-mould.ht...









Uploaded by: ecfibreglassuk. Video Description: This is a Video demonstration showing how to make a fibreglass mould. Tags for this video: {{2}} Category: ...* The Series. by GasserGlass 98 ...

.about halfway into it you can see what fiberglass or carbon fiber looks like on the outside as you lay it up then what the mold looks like on the inside at the end ... decide which looks better

louanneyis

It would be great to see pics after the body shop has finished fairing it out.