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      04-06-2013, 03:43 PM   #1
inTgr8r
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DIY - Fangs repair & reflectors fill

I've had this on my to do list ever since I got the Coupe.
I finally got it done.

This started out as a simple fangs fix.
I had zero luck tying to find someone local to plastic weld the reflector openings, so decided to do them as well.

Overall its pretty straight forward body work, except for the materials.
You have to use products specifically designed for flexible poly bumpers

The products...
- bumper repair epoxy
there are many different brands and packaging that this comes in.


Since I was doing a little more extensive work, I picked up similar product from a body shop supply.

- support mesh
for the reflector fill, you need to provide support across the opening.
for this I found some aluminum mesh.
The one I found was actually flat plate aluminum that had been punched into a mesh.
For this you will have to dig up what ever is available local to you.


The FANGS

- The first step is to just clean them up &sand down the surrounding paint.
- second is to rough up the area to be filled. This is a very important step as the rough surface give the epoxy more to bond & lock onto.
- clean the surface & then start building up the repair area with epoxy.
- depending on your choice of bumper epoxy, check the working time.
the one I used was about 2 minutes.
- mix small amounts that you can use right away and dont try to fill it all in one pass.
- build it up in layers, sanding between each coat.

A few of my fang pics...
..unfortunately I didn't think to take any 'before' pics. My damage was mainly at the corner and edge.

pic1
This is actually after the 2nd fill.
You can see that the lines are not fully restored, but the basic shape is getting there.
This product sands very easily but the first coats are easier to shape down with a course file. (you will need a file wire brush to keep it clean)


pic2
Lines are pretty well restored, just needs final fill & blending.



pic3
Almost ready for paint


pic4
Just back from the paint shop. (both fangs had the same damage)
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      04-06-2013, 03:43 PM   #2
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Fill in those openings....

A bigger challenge to the fangs was filling in the reflector and squirter openings.
Not really more difficult, just a bigger job.

The first step was to cut back some of the plastic behind the openings.
You have have to support across the opening, and you have to provide a good amount of surface area for the epoxy to adhere to.

pic1
In this pic you can see how some of the plastic was cut back and also see how the surface is roughed up.
After the plastic was cleaned with acetone & sanded with course paper, the surface was roughed up with a rasp file.


pic2
This is the aluminum support mesh laid roughly in place.
This mesh gets embedded in the epoxy.



pic3
Similar pic to above showing plastic cut back & mesh for squirter openings.


pic4
This the support mesh bonded in place.
-spread the epoxy on the bumper surface; press the mesh down into the epoxy; then trowel on more epoxy to cover.



pic5
This is the front side showing a donor piece cut to fill the opening.
- NOTE how the edges are feathered back on both the opening and on the bumper fill piece.
I used a half round rasp for this.
This is a really important step in getting a strong bond.


pic6
This is the first rough fill coat.
Don't try to be too fancy, just make sure that its worked into that feathered edge joint.
You don't want any trapped air bubbles at this stage.


pic7
The second pass.. still some more to fill. (rear bumper)


pic8
Almost ready for paint; final blend pass still needed.


pic9; 10
Back from paint....

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Last edited by inTgr8r; 04-06-2013 at 05:18 PM..
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      04-06-2013, 04:06 PM   #3
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      04-06-2013, 05:15 PM   #4
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Great Job!
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      04-06-2013, 08:50 PM   #5
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Very nice. Thx for write up. I plan to do this next winter. Similar damage on fangs; want to delete reflectors. Pictures are really helpful.

Your result looks great!
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      04-06-2013, 09:20 PM   #6
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Awesome work! Unfortunately a little ambitious for me.
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      04-06-2013, 09:24 PM   #7
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Yup. Looks incredible. DIY is wonderful.

I'm going to have Krissi do hers then mine. She works with resin and epoxy all the time--perfect match for her skills. Probably next fall.
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      04-07-2013, 08:57 AM   #8
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Quote:
Originally Posted by Caddyshk View Post
Great Job!

...just wish this weather would warm up more for us.

Quote:
Originally Posted by sinbad4 View Post
Very nice. Thx for write up. I plan to do this next winter. Similar damage on fangs; want to delete reflectors. Pictures are really helpful.

Your result looks great!
Thanks,
it's a pretty straight forward DIY.

Quote:
Originally Posted by itdnwiwbp View Post
Awesome work! Unfortunately a little ambitious for me.
thanks
Quote:
Originally Posted by Finnegan View Post
Yup. Looks incredible. DIY is wonderful.

I'm going to have Krissi do hers then mine. She works with resin and epoxy all the time--perfect match for her skills. Probably next fall.
I didn't think about that...
This will be a great DIY for her.
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      04-07-2013, 01:05 PM   #9
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Just had this done as well, very happy with the results. I was considering doing some of the prep myself but heck of a mess to clean up in my apartment
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      04-07-2013, 01:19 PM   #10
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I have to get my bumpers and hood repainted and my fangs fixed, so since I am there will have them do the delets as well.
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      04-07-2013, 01:38 PM   #11
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Quote:
Great Job!


...just wish this weather would warm up more for us.
I've not even taken the car off the charger yet. Weather just sucks - everything I enjoy delayed
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      04-07-2013, 04:21 PM   #12
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Nicely done. Those fangs are fresh from-the-dentist clean
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      04-08-2013, 08:21 AM   #13
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Great job! Notice that you also filled the headlamp nozzles.
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      06-11-2013, 07:21 PM   #14
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Thanks so much for this DIY. I have an M Bumper downstairs waiting the exact same repairs.
Getting info on bumper repairs has been a bit of a chore. Most suppliers of the repair kits are not very knowledgeable of confidence inspiring.

A couple of questions..

Your donor material to fill in the reflector ports..Did you use the plastic that you trimmed from the washer supports ?

On installing the bumper. Im going from a facelift to the M Bumper. I have studied the parts list and except for some sticker shock (2 brake ducts, 2 support brackets, and a tow hook cover priced out at $285 plus 13% tax )
I have been warned by a couple of Zedders that I also need a metal support / bracket for the lower bumper. Actually it was called 'the metal thing" ...

Can anyone comment on these concerns ...

Cheers
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      06-11-2013, 09:19 PM   #15
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Filler pieces were from a scrap piece of bumper I had from another car.
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      06-12-2013, 12:59 PM   #16
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OoOoOoOoHh!!! Nicely done!

I'll defnintely have to try this when I get home. Question. I got backed into, slowly but hard enough to dent the piece between the kidneys and chip away the paint. Think this will work for that as well? If I screw it up, I planned on getting a new fascia anyway lol so no worries there.
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      06-12-2013, 01:20 PM   #17
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Quote:
Originally Posted by 007MCoupe View Post
OoOoOoOoHh!!! Nicely done!

I'll defnintely have to try this when I get home. Question. I got backed into, slowly but hard enough to dent the piece between the kidneys and chip away the paint. Think this will work for that as well? If I screw it up, I planned on getting a new fascia anyway lol so no worries there.
Thanks
You can see in pic 2 and 3 the spot above the fang where I had a similar ding to fill.
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      09-15-2013, 11:44 AM   #18
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Thanks inTgr8r
With your guidance ..
My M Bumper



Repaired



Back from the painter !


I couldn't have done this without your help !
Thanks
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      09-15-2013, 11:53 AM   #19
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I used a donor bumper I retrieved from the dumpster behind the local Ford dealer.
To fill the reflector ports I discovered that the port had two chamfers ..1/2 of the port was bevelled in one direction, the other half in the opposite direction. I cut a filler piece to match and it snapped right into place. I needed two layers of filler to bring the repair up to proper level.
The washer ports ..I didn't remove much of the washer support. And I managed to slide repair mesh between the support and the bumper. Contrary to the original pics my bumper had sustained quite a bit of a twist when it was damaged and I felt it needed as much reinforcement as possible.
After some discussion I also filled the tow hook port and plan on locating the front lic. plate lower - in front of the grill.
A heat gun was invaluable in carefully returning the fangs to original position and destressing twisted areas.

Thanks again.
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      09-15-2013, 12:09 PM   #20
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Other Bumper Mods Im considering ...

Colour matched Brake cooling ducts with fog lights relocated





And colour matched kidney grills with shadow chrome trim



Front plate relocation ?



The jury is still out on the aesthetics of colour matching. The brake ducts were considered because I feel the depth of the port will look better as the same body colour. The kidneys ..Well I have 3 sets of those now. Argent, black and white. So it's an easy fix if I don't like how it looks.
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      04-09-2014, 11:38 AM   #21
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Hi!

I have a question for the guys who have filled the gaps. Can you tell me if there are cracks appearing on those areas? A friend told me that one problem that might show up is that if you hit the bumper (slowly) those areas will crack quickly.

What product (brand) have you used to fuse the plastic parts with the bumper?
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      04-09-2014, 09:06 PM   #22
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Anyone?
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