Molding 01-02 WW kit onto 98-00 bumper like never before

[KnightRyder]

I've been working on this project none stop for a couple weeks now, a few of you have seen updates via facebook but i decided to finally let the cat out of the bag since im approaching the end of the project.

Front lip is the 01-02 Accord Coupe Wings West Lip. but im mounting on the 98-00 bumper because i like that bumper better for the look im trying to achieve. rest of the kit is the normal Wings West kit.

What separates me from all the rest of the people who mold kits, specifically this WW kit, is that im molding it to the point where it wont look like a lip kit anymore, completley flush. most people who mold their kits, end up spending a lot of money to mold the kit, only to still have it look very much like a lip kit still.

i seeked the assistance of none other than Nexson for this project and i pretty much followed what he told me to do, i've done smaller projects in the past which he has helped me with so i have a general understanding of what to do but i can always learn more from him.

Products used....
Fusor 602EZ (plastic to plastic adhesion promoter)
Fusor 152 (the main adhesive that is used for molding)
Evercoat FiberTech (main filler used to achieve the look i wanted)
Evercoat PolyFlex (finer filler used to finish off)

theres a LOT of pictures so be patient. ive been posting daily updates on my team's site so im just copying all those posts here so ignore the tenses and whatnot, you guys are getting it all at once.

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today is the first official day i did any work on the car with the new Wings West kit. If you dont already know, im molding the kit onto the bumpers for a flush look, when im done with it, you wont even be able to tell it is a lip kit, its going to look like a full body kit.


I 3m taped the rear lip onto the bumper after i scuffed the paint down in the area. im only using the 3m tape as my guide so that i can step back and take a look at how im going to proceed.

the one area where it doesnt quite fit but its no big deal, i can make it work.

tomorrow i plan on starting the drilling. what i mean by drilling is that where the lip touches the bumper, im going to drill a 1/8" hole every inch or so along the entire joint so that when i apply the adhesive that is going to hold the lip kit on the bumper permanently, the adhesive will ooze into the holes and provide a better bite so it will hold stronger.

also tomorrow i will probably do the same thing with my front end, 3m tape and drill the holes hopefully if i have time. i have to work tomorrow and go shopping for my families camping trip this weekend. busy day.


theres no going back now. wish me luck. i pray im going to be done in time for japantown.

 

[KnightRyder]

decided to drill the holes today since i may not have time tomorrow if im working with my dad....

also put like 5 screws in JUST IN CASE as a temporary means to hold the lip on the bumper. because as much as i love 3m tape, i dont trust it to be the ONLY thing holding up my heavy lip. the screws will be removed later of course...

 

[KnightRyder]

had a little time today to try to figure out how to securely mount the side skirts. i added many more screws that the kit actually calls for because they rely tooooo heavily on the 3m tape to hold this heavy *** side skirt up, i dont trust 3m that much.

so i fabricated a sturdy "L" bracket for the rear and used a solid mounting location in the front, also drilled 3 holes in the door sill area and put 3 screws there, plus the 3 or 4 screws that i still need to add underneath.
when i get a chance to put the car on the lift i will be adding an additional custom "L" bracket to both the front and rear of the skirt so that i will have 2 secure mounting screws in front, 3 in the door sill, 3-4 underneath the car and 3 at the back of the skirt. as it sits right now, there is 1 in front, 3 in the door sill, 0 underneath the car and 2 in the rear.


1 of the custom rear "L" brackets i made screwed into the cars body, its super solid but im still adding one more in this area.

one of the 3 screws in the door sill area. will have to buy a countersink drill bit and use some countersink screws so they dont look super obvious when i open the door. they'll be flush with the surface of the skirt so then i can just apply some gloss black vinyl over it so it'll blend into my paint and you wont even see them.

 

[KnightRyder]

more work today...

cutting the holes for the new fog light openings. the lip is made for the 01-02 bumper, this is a 98-00 bumper so there are some differences.

front lip mounted. the 3m tape on the front lip was total crap, super stiff, didnt want to stick very well. so i had to use a lot of screws to keep it from falling off, just like i did for the rear.

i will relocate my fog lights into the new locations and then fill the rest of the areas with a tight small diamond mesh grill which will be used throughout the entire front bumper.

 

[KnightRyder]

day shots:

 

[KnightRyder]

Major thanks to Eddie and Jeff for lending a hand today with the molding of my front and rear lips. couldnt have done it without their help.


sanded the paint off the bumper to provide a rough surface for the adhesive to bond to. also sanded the back of the lip in the same way.

masking off the areas where i dont want the spray on adhesion promoter

one bead of adhesive applied to the back of the lip, one thick bead applied to the bumper, and then one more bead applied on top of the joint for added security. nice and messy but this thing is solid now. i dont really need the screws but im going to counter sink them into the lip just because it'll give me that much more piece of mind.

molded... waiting for it to cure overnight then i'll begin sanding it smooth and prepping for the body filler to do away with the edges you see. its going to be smooth...

 

[KnightRyder]

more work today. not as much as i had hoped but still progress. was hoping to get some filler applied today but never got around to it. spent 3+ hours sanding! (with a power sander!!!!)

sanding off the paint, prepping the surface for the filler

i sanded the top portion of the lip as flat as i could since it sort of had a slight curve on it and still does it some spots but its much less noticable now. i want the surface to be as flat as possible.

you can see that i took the time to counter sink at least a dozen screws below the surface on both the front and rear lips. but after talking with my friend who's helping me through this project, he advised against using any sort of hardware because if the bumper flexes then the metal screws wont and that might cause the filler in the area of the screws to crack. so instead im going to inject all the screw holes now with Fusor 152, the same stuff i used to bond the lip to the bumper

after 3+ years of living with this damn rash from a hit and run, im finally fixing the rash!!!

you can see that we did a decent enough job filling the edge with the Fusor 152 but of course there will be more filling involved but this at least give you a rough preview of how its going to be blended in.

im aiming to have the first stage of filler done tomorrow. and then the 2nd and 3rd stages Friday. and then a lot of fine FINE sanding on sunday, then off to paint on monday. Apex told me they only need 3 days so thats why im pushing my deadline to monday instead of friday, that way i can work at my pace and not kill myself trying to finish in time.

 

[RICKDIGILER]

Great Job Dude!
Mad Props...

 

[KnightRyder]

and the work continues.... 1st layer of filler applied. Evercoat FiberTech

$35 a pack, ran through 2 of them :-[

yummy, lol

applied it in 3 stages to get it built up this thick buts pretty darn flat right now for being a rough filler. a little sanding and i'll be ready for the fine filler.

rear didnt need as much as the front.

damn chemicals smell really "good" but of course are bad for you so.... protecting my lungs.... cant smell a damn thing in this....

 

[KnightRyder]

so much sanding, fcuk!!!!!!! didnt even get a chance to apply the next fine layer of filler like i wanted. that will have to go on tomorrow and get sanded later in the day.


pie cut the ends because they hung pas the bumper so much and then plastic welded it back together.

filler applied on the ends of the lip/bumper. got the rough shape smoothed out.

sanded relatively flat, getting it ready for the next stage of filler.

i wont be able to get the ends as straight as i wanted. too complex with the shape of the lip. owell, will do my best.

roughly shaping the backside of the bumper/lip where they meet.

layer of dust all over the car from all the sanding i did. crazy.