Plugs for bumpers

Due to the mass of the bumpers, a slightly different procedure was called for to accommodate larger areas. First a mold was formed around the car where the bumper would be. Plain cardboard was sufficient since it wasn’t really necessary to make a specific shape, just leave enough excess foam to carve away when shaping.

When the cardboard mold was mocked up, we poured in a mixture of liquid foam mixed 50/50 with catalyst. As this foam dries, it expands through the open area and leaves us with a large foam shape similar to the 4 lb. polyurethane foam that was used for the scoops.

The rest of the process is pretty much the same.

    Rich tip:  Carve away on only one half of the car. Use this half to make reference templates to mirror the other side. It took seven templates made out of cardboard and bondo for the front bumper alone..

Once each plug has a smooth, polished finish, it is time to make the molds. This is a whole different process that requires more detail and a lot of steps. So we’ll end here for now. Next month’s new article will teach how to make your own molds from your new plugs.

With these procedures, the sky’s the limit on how many different custom parts can be made from fiberglass -- including your own custom body kit. With these molds you will have the tools to create your own production line. Until then, try making your own plugs and I’ll see you next month to finish everything off.
    
Rich Evans, owner of Huntington Beach Bodyworks in Southern California, is an award winning painter and fabricator. Currently he is offering workshops at his facility so he can share his special techniques to other industry professionals. For more information about Evans, visit www.huntingtonbeachbodyworks.com.