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  1. #1
    Veteran Member Four Rings
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    Ultrasport lower with stock upper bumper how-to (lots of pics)

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    1) remove bumper from car. remove lower "half" from upper. I put half in quotes b/c as you see, the upper part extends the whole height of the bumper:




    2) cut away any parts that will interfere with the ultrasport lower lip sitting flush. I used a utility knife and a dremel. I cut away more than I needed to it turns out, mostly from the section that separates the center grille area from the L/R grilles:



    this is about how much I cut away:



    here's a closeup of the trimming required near the fogs (same on boths sides so I'll just post one pic:



    make sure everything fits:








    the two center beams of the U/S lip (for lack of a better term) won't fit on top of the upper bumper because the curvature is a little different. You could cut them some, but I didn't want to lose any more structural support, so I didn't worry about it.

    once I was satisfied with the fit, I went ahead and painted black the areas that would be visible once the U/S lip was fitted, the fog surrounds and the 2 center supports. Note that you don't need to paint the fog surrounds if you are using the stock USP fog grilles.







    While I was waiting for that to dry, I went to work on the grilles. I used .75" expanded metal mesh from Home Depot, $15 or so.




    I created cardboard templates since I don't have the U/S grilles to use as a guide. It took a lot of trimming with the dremel, and after I was happy with the fit, I painted them with Plasti-dip rubberized coating ($5 at HD). 3 coats, 30 mins in between coats, let dry overnight. The center grille opening is 27" but the grille sheet is only 24" (largest I could find), so I had to use tiny zip ties and some epoxy to attach two pieces together. Fortunately the ends are cut right down the center of a diamond, so matching them up was no problem. I'd be willing to bet you can't tell where the break is.




    I used self-adhesive rubber door trim as a border for the grilles, don't have any pics of it separate, but it was about $12 for a 25' roll.

    back to the main event. Once the black paint on the stock upper bumper is dry, it's time to attach the U/S lower lip. I used a combination of epoxy, zip ties, and machine screws. I drilled one hole in each of the tabs on the U/S lip, 1 hole on each side of the two center beams, and two holes on each side where the U/S lip attaches near the fogs.

    After the holes were drilled, I mixed up some epoxy and spread it on the stock upper bumper on the areas where the U/S lip would overlap. Then I attached the U/S lip and secured it with the zip ties before the epoxy dried.

    here's the back side of one of the center beams showing the zip tie:




    here's another showing the back side of the fog lamp area:




    Next I drilled 1 hole through each of the center supports straight through the U/S lip. I used a small machine screw with washers on either side and a nut on the bottom (with threadlock of course).

    pic of the screw from the "top":




    and one from the bottom. I dremeled off the excess screws at the nuts after I took the pic




    and that's it for the bumper. There are NO issues with the U/S lip not being secure, even with the amount of cutting done. It doesn't wobble or sway or move an inch even at or above highway speeds.

    Attaching the grilles was pretty easy. I cut them to fit pretty eactly so they fit snugly and really didn't need anything to secure them, but I used a few tiny zip ties just to be sure. Sorry no pics of that as my camera sucks and none of them turned out. The side grilles you have to attach *after* the bumper is put back on the car unless you have mad skills.

    Here's some gratuitous pics of how it turned out, from various angles in the daylight:

    front:



    driver front 3/4:



    pass front closeup:



    pass side w/refinished wheels:




    and some more current pics, with blacked-out upper grille trim and S4 e-codes:







    Thanks for reading, and please post/email/IM me with any questions. I'm sorry more of the pics didn't turn out.

    **Disclaimer: semi-professional modder on a closed course. Do attempt this at home.
    Last edited by Matt Devo; 11-29-2012 at 12:13 AM. Reason: updated pic links
    2002 A4 2.0TQ 5M. 217k+ mi

    FWD->AWD
    Bische tuned GT2871R/750cc, JHM RS4 clutch, ER Sport FMIC, 034 HFC/Mototec exhaust
    DIY 4:1 diff, B5 1.8T trans
    custom bixenon e-codes, USP front lip, Zender spoiler, DTM sideskirts, S4 rear
    Stoptech 355mm front / B7 S4 rear brakes, Eibach COs, 034 RSB, Sportec Mono 10s
    B6 S4 Recaros, Euro shift knob, JHM SS + linkage, B7 console, RS4 pedals, oCarbon blue CF trim
    RNS-E, TT-S MFSW, color cluster, Alpine PDX-5, Polk DB-6501, IDQ sub/LosLabs box

  2. #2
    Veteran Member Four Rings A4 - Oh Snap's Avatar
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    Irvine, CA

    Very nice. No one will ever know.

  3. #3
    Veteran Member Four Rings Saturnine's Avatar
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    03 A4 Avant, 85 ABA Golf
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    Damn that looks nice
    '03 Audi A4 Avant, lightly modded My name is John.

  4. #4
    Veteran Member Four Rings flyinb501's Avatar
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    '02 Audi A4 1.8TQ MT5, 2000 CB
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    Wow, nice job. Huge improvement.
    '02 A4 1.8TQ MT5: Revo tuned k04/ Eurocode FMIC, testpipe/ Neuspeed exhaust, snub, SS/ Forge DVR/ 19" Sevas/ S4 blades/ Painted Lowers/ VDO boost gauge/ Tein springs/ Lip spoiler/ Blackout grilles/ Icelink/ Alacantara shift boot

  5. #5
    Senior Member Three Rings
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    2003 A4 1.8T Quattro
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    Chicago, IL

    super job.. seems like i hvae a new task for my bodyshop!!!

    just one question.. wouldn't it be possible to use the OEM fog grills?

  6. #6
    Registered Member Two Rings
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    03 A4 QMtS 77 Blazer 4x4
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    Sacramento, CA

    very nice, now get the blackout upper grill :)

    Jay
    Jay

  7. #7
    Veteran Member Four Rings Tinman's Avatar
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    Aug 25 2004
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    My Garage
    nice n' low a-fo, 2006 Saaburu, 1978 Corvette
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    Fairfax, VA

    looks hot, matt! very nice. you should make those lower grills and sell 'em. heh, I'd buy one!

    L8
    ~ben
    no TURBO, no CARE.
    pics of the car: the original BB USP w/ gunmetal RS4s
    407awhp and 408awtq on a Mustang with 93oct and meth. still 1.8L

    GOT EFR? (543chp/544clb-ft)

    Twitter: t1nman

  8. #8
    That looks pro, good job. Definitely one of the better DIY grille projects.

  9. #9
    Stage 2 Banner Advertiser Four Rings winston@podi.ca's Avatar
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    Pods, gauges and more pods
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    That's a great mod job.

    Excellent end reult and it looks sharp.


  10. #10
    Veteran Member Three Rings RASTA4's Avatar
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    Feb 26 2005
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    My Garage
    2002 A4 3.0
    Location
    Metro Detroit

    Nice work. Can't wait to see the matching upper grill. That sure beats spending +/- $1000 on a complete USP bumper conversion.
    |2002 3.0 SEDAN Q6MT|POLAR WHITE|PLATINUM BUFFALINO|SPORT|CONVENIENCE|COLD|BOSE|BNS-NAV|PARKTRONIC|SUNSHADES|ODO=34XXX|

    MODS
    |PES G3 SC|SUPERSPRINT|AFE PRO-DRY|18x8 BBS RE-G FORCE SPORT|17x8 BBS RC-CONTIEXTREME|H-SPORT S4 SWAYS|AMS SS|APR SNUB|STOPTECH 332 FRONT-BREMBO X-DRILLED REAR|HAWK HPS|SS LINES|OPTIMA-REDTOP35|XENON ECODES|LED CITYLIGHTS|HOEN|SYMPHONY II+|DICE|35% SOLAR GARD|S4 DOOR FLARES|MOTUL 5.1|MOBIL 1 0W40|

  11. #11
    Veteran Member Four Rings hyperspeed's Avatar
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    2011 M3
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    wow... i love it!

    and the job u did was great with the matching and eveyrthing. good job

  12. #12
    Veteran Member Four Rings shehatezme's Avatar
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    Damn looks good , nice DIY!!!!

    Took 2 years for someone to figure this out.

  13. #13
    Veteran Member Four Rings
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    Originally posted by adrianma
    just one question.. wouldn't it be possible to use the OEM fog grills?
    sure, all the OEM grilles would work just fine. I could have used the OEM fog grilles and just made the center one, but the grille pattern would not have matched exactly, and even if they did, they cost more than I'd want to spend.
    Last edited by Matt Devo; 03-06-2006 at 11:25 AM.
    2002 A4 2.0TQ 5M. 217k+ mi

    FWD->AWD
    Bische tuned GT2871R/750cc, JHM RS4 clutch, ER Sport FMIC, 034 HFC/Mototec exhaust
    DIY 4:1 diff, B5 1.8T trans
    custom bixenon e-codes, USP front lip, Zender spoiler, DTM sideskirts, S4 rear
    Stoptech 355mm front / B7 S4 rear brakes, Eibach COs, 034 RSB, Sportec Mono 10s
    B6 S4 Recaros, Euro shift knob, JHM SS + linkage, B7 console, RS4 pedals, oCarbon blue CF trim
    RNS-E, TT-S MFSW, color cluster, Alpine PDX-5, Polk DB-6501, IDQ sub/LosLabs box

  14. #14
    Veteran Member Four Rings A4rce1's Avatar
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    London

    You did it! Thats awesome and everyone said it couldnt be done

    It looks flawless, congrats

  15. #15
    Registered Member Four Rings |Sandman|'s Avatar
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    A6 3.0 TDI QTip
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    congrats man !!! that looks AWESOME.. very good job
    2005 Audi A6 3.0 TDI Quattro | 2002 Supercharged 330ci
    AKA Silveraudi

  16. #16
    Veteran Member Four Rings audidood's Avatar
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    correction: only 2 years for someone to have the balls to just bust out the dremel and go to town.

    Nice work on the bumper, and i love how all the grills match. Good job!
    Originally posted by shehatezme
    Damn looks good , nice DIY!!!!

    Took 2 years for someone to figure this out.
    2004.5 USP A4 1.8t with mild mods.
    1956 VW Bug with major mods.

  17. #17
    Veteran Member Four Rings DoThisMyWay's Avatar
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    Nice work! Looks great!
    2006|A4 Avant 2.0T Quattro S-line
    2005|A4 3.0 Quattro UltraSport

  18. #18
    Veteran Member Four Rings element256's Avatar
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    Is about to change completely
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    SoCal IE

    bout time someone did this... good job man and nice writeup...Alot of people will be using this I'm sure.

  19. #19
    Veteran Member Three Rings 9744RR's Avatar
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    Great job and it looks clean.
    Hers 2003 A4 1.8TQ TIP - GTRS Eliminator, REVO, Delphi 440's, ASP FMIC, Extreme TIP, Labree HFC, TT-DP, S4 door blades.
    2012 Mini Cooper - Stock


    Mine '64 Porshe 356, '12 A6 3.0T Prestige - stock

    Our Minivan has 240+ HP and its quicker than STG 1, 1+ A4's

  20. #20
    Senior Member Three Rings jokas's Avatar
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    2003 Audi A4 1.8T Quattro
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    North Jersey

    that is fantastic!! wish i had the skillz... would really like to get the USP Front for my car.

    Great Job!!

  21. #21
    Veteran Member Four Rings A4Technik's Avatar
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    Aug 08 2005
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    My Garage
    Porsche 944 Turbo / Audi A4 Front Trash
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    Thats awesome....
    Garage:
    1993 KS Auto Burnout Widebody Rx7
    2005 Kraftwerks Supercharged s2000
    2006 Evo IX MR
    2005 Audi A4 1.8T - Sold

    Go Fast Goodies:
    K-03 Sport | ER Sport FMIC | ER Test Pipe | ER Rebar | EVOMS CAI w/ HKS Super Mega Flow | Neuspeed Catback | REVO BI | BOSCH 380cc Inj. | STRATMOSPHERE Hyperboost DV

  22. #22
    Veteran Member Four Rings GTRchop88's Avatar
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    2005 Audi A4 USP 1.8TQ 6-speed
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    Items for Sale

    Nice
    USP CLUB MEMBER #7
    Big Turbo 2005 Audi A4 USP 6-speed
    Forge/ATP/Spec/Garrett DBB 50 Trim/Magnaflow/StreetEdge/Tial/Turbosmart/AEB/ARP/Eagle/034/Recaro/Walbro/Bosch/Brembo/Apikol/SSR/AEM/VEI
    Things for sale: http://www.audizine.com/classifieds/...00&ppuser=3228

  23. #23

  24. #24
    Veteran Member Three Rings
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    cape cod

    Nice! Now I can finally have the u/s lower that's been sitting in my basement for a year and a half painted and installed. Thanks!

    Are there any issues with the belly pan lining up correctly?
    http://i78.photobucket.com/albums/j1...gpicCustom.jpg
    QED Built Motor/PP'd head, Revo GTRS.

  25. #25
    Veteran Member Four Rings LAZY TURBO's Avatar
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    La Crescenta, CA

    looks really clean, nice job!!
    ~Sevan

    USP CLUB MEMBER #1 <~CLICK IT

  26. #26
    Veteran Member Four Rings
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    Items for Sale

    Originally posted by jayt991
    Are there any issues with the belly pan lining up correctly?
    nope, everything lines up as before
    2002 A4 2.0TQ 5M. 217k+ mi

    FWD->AWD
    Bische tuned GT2871R/750cc, JHM RS4 clutch, ER Sport FMIC, 034 HFC/Mototec exhaust
    DIY 4:1 diff, B5 1.8T trans
    custom bixenon e-codes, USP front lip, Zender spoiler, DTM sideskirts, S4 rear
    Stoptech 355mm front / B7 S4 rear brakes, Eibach COs, 034 RSB, Sportec Mono 10s
    B6 S4 Recaros, Euro shift knob, JHM SS + linkage, B7 console, RS4 pedals, oCarbon blue CF trim
    RNS-E, TT-S MFSW, color cluster, Alpine PDX-5, Polk DB-6501, IDQ sub/LosLabs box

  27. #27
    Registered Member Four Rings HighPSI's Avatar
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    Jun 30 2004
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    DC

    nice job matt, looks real good...

  28. #28
    Veteran Member Four Rings Saturnine's Avatar
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    Feb 11 2004
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    15
    My Garage
    03 A4 Avant, 85 ABA Golf
    Location
    Palo Alto, Ca

    You dont have any pics of just the lower USP portion do you? I've found myself with an upper bumper to play with..
    '03 Audi A4 Avant, lightly modded My name is John.

  29. #29
    Veteran Member Four Rings
    Join Date
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    best one I've got:

    2002 A4 2.0TQ 5M. 217k+ mi

    FWD->AWD
    Bische tuned GT2871R/750cc, JHM RS4 clutch, ER Sport FMIC, 034 HFC/Mototec exhaust
    DIY 4:1 diff, B5 1.8T trans
    custom bixenon e-codes, USP front lip, Zender spoiler, DTM sideskirts, S4 rear
    Stoptech 355mm front / B7 S4 rear brakes, Eibach COs, 034 RSB, Sportec Mono 10s
    B6 S4 Recaros, Euro shift knob, JHM SS + linkage, B7 console, RS4 pedals, oCarbon blue CF trim
    RNS-E, TT-S MFSW, color cluster, Alpine PDX-5, Polk DB-6501, IDQ sub/LosLabs box

  30. #30
    Registered Member Two Rings
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    Issaquah, WA

    Superb...

  31. #31
    Senior Member Two Rings
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    My Garage
    B6 A4 3.0
    Location
    Vancouver, Canada

    Nice job there, Matt Devo.
    BTW, what's the name of the colour on your car? That blue looks great!

  32. #32
    Senior Member Three Rings NightRider's Avatar
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    Sep 18 2006
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    Sandy, UT

    wow man, beautiful job. I will be attempting this shortly...
    2003 Audi A4 1.8TQM Blacked Out APR Exhaust Clear Corner 19" Falken Koblenz Stasis SS JHM Short Shifter APR Snub 35% tint

  33. #33
    Veteran Member Four Rings toaster's Avatar
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    Sep 16 2005
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    My Garage
    Gone:A4 USP+ / A4 S-Line+
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    long island, ny

    it's baaaaack....

  34. #34
    Veteran Member Three Rings pdxa4's Avatar
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    12 Golf-R, 03 S8, 08 GTi, 06 MX-5
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    Very nice work, came out looking amazing...
    Current: 12 VW Golf-R, Rising Blue
    Former: 03 S8, Ming Blue
    Former: 08 GTi, 4dr DSG
    Current: 06 Mazda NC MX-5 many mods
    Former: 03 B6 A4 Avant 1.8TQ
    Former: 00 B5 A4 1.8TQM J31-K04
    Former: 04.5 Euro Passat PD TDI

    Original PDX
    V1.0 Member since 02/24/2002
    Matrix Integrated**

  35. #35
    Veteran Member Three Rings JWERNER24's Avatar
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    1983 Porsche 944 (Track Toy), 1997 Toyota 4Runner (Offroad Toy)
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    I followed this How-Do when I did mine... well done!
    Sold: 2002 Ming Blue A4 3.0 MT6Q
    Current: 2001 Brilliant Black allroad 2.7tQ

    FOR SALE: 1983 Porsche 944 - PM for details!

  36. #36
    Veteran Member Four Rings seph's Avatar
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    y was this never moved to the DIY section....
    -Ant
    2012 A5 2.0TQ 6MT Ibis white

    2002 A4 3.0 TIP Quattro - Sold

    For sale: ADR M-Classics 19" w/ Toyo proxes 4s- DTH USP splitter

  37. #37
    Registered Member Two Rings Uber Hans's Avatar
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    Chino Hills

    please move it to the DIY

  38. #38
    Veteran Member Three Rings 617 Bones's Avatar
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    Sep 15 2006
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    My Garage
    Wife's - MK3 GTI VR6 Vortech S/C
    Location
    Boston

    Anyone know if this MOD wiggles or wobbles at all??
    it looks awesome, but with winter and alot of snow coming soon, will this DIY bumper be able to take a little abuse or is it somewhat flimsy??

    thanks!
    Last edited by 617 Bones; 11-08-2006 at 02:59 PM.

  39. #39
    Veteran Member Four Rings gq9's Avatar
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    Nov 07 2006
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    02 A4 1.8t
    Location
    New York

    Originally posted by pdxa4
    Very nice work, came out looking amazing...

  40. #40
    Veteran Member Four Rings Monizzle's Avatar
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    Dec 27 2005
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    Mercedes S550, 2012 Audi A4 quattro
    Location
    Los Angeles

    Originally posted by 617 Bones
    Anyone know if this MOD wiggles or wobbles at all??
    it looks awesome, but with winter and alot of snow coming soon, will this DIY bumper be able to take a little abuse or is it somewhat flimsy??

    thanks!
    if you do it like Matt it won't wiggle or wobble.

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