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View Full Version : Building your own rs4 bumper...



iwasawesome
04-04-2007, 05:48 PM
http://forums.audiworld.com/a4/msgs/2681016.phtml

i suck at html...

TQMB5
04-04-2007, 06:00 PM
did that start as a s4 bumper?

loustylez
04-04-2007, 06:07 PM
that's a pretty common mod actually. referred to as "the modded S4 bumper".

Speckto
04-04-2007, 06:16 PM
would be interesting to see how he plans on getting the side air vents in there

iwasawesome
04-04-2007, 06:22 PM
yep it started as an s4 bumper

iwasawesome
04-04-2007, 06:24 PM
would be interesting to see how he plans on getting the side air vents in there

Side air vents ? Huh?

The grills are removeable like the s4 bumper... and I have a fmic so i don't need an intercooler shroud. I have rs4 mesh on order. It will function just like a normal s4 bumper..

yeah it's called the JustDave mod, he has a tech article on how to do it ... audiworld tech archives

mike-2ptzero
04-04-2007, 06:26 PM
that's a pretty common mod actually. referred to as "the modded S4 bumper".

Known as the RS4 mod to a S4 bumper, AKA the "Just Dave" mod for the old school guys [:D]


He didn't look like he did a very good job at filling in those holes left by the center bar. There is a much easier way to do it then using bondo, by using resin/FG like cotton candy.

Speckto
04-04-2007, 06:29 PM
Side air vents ? Huh?

The grills are removeable like the s4 bumper... and I have a fmic so i don't need an intercooler shroud. I have rs4 mesh on order. It will function just like a normal s4 bumper..

yeah it's called the JustDave mod, he has a tech article on how to do it ... audiworld tech archives

http://www.lltek.com/images/rs4_blue_02.jpg

do you have another name for these?

iwasawesome
04-04-2007, 06:31 PM
Known as the RS4 mod to a S4 bumper, AKA the "Just Dave" mod for the old school guys [:D]


He didn't look like he did a very good job at filling in those holes left by the center bar. There is a much easier way to do it then using bondo, by using resin/FG like cotton candy.

I looked at the fibreglass as you mentioned... i found the bondo to be "easier" because i had experience with it.

The holes are very smooth and level, i do need to do some "fine touch ups" .. i guess paint will tell how good my work was. Thanks for the advice though mike, i did appreciate it

iwasawesome
04-04-2007, 06:32 PM
http://www.lltek.com/images/rs4_blue_02.jpg

do you have another name for these?

oh... Ha, sorry im not adding those.

Beemer832
04-04-2007, 06:39 PM
here check mine out.. i LOVE IT.. althoguht the inserts on the sides dont fit flush ALL the time because the FMIC is a bit TOOO big....

http://www.audizine.com/gallery/data/500/3560front.jpg

josh

Beemer832
04-04-2007, 06:40 PM
o yea thats an A4 btw, not an S4..
josh

ianlionzion
04-04-2007, 06:45 PM
I followed the AW tech article as well, its gonna look like this.

http://images105.fotki.com/v456/photos/3/356984/1264722/IMG_1140-vi.jpg

While your at it, have you thought about filling in the washer vents?

Quattro
04-04-2007, 06:59 PM
Ive seen it in person, it looks nice if done correctly

iwasawesome
04-04-2007, 07:00 PM
naw gonna leave the washer vents. I like the way they look.. I know they aren't practical.. but no big deal.. They are there, and they aren't harming anything

mike-2ptzero
04-04-2007, 07:46 PM
o yea thats an A4 btw, not an S4..
josh

Pretty sure everyone figure that one out because of the single inlets on both sides of the fmic.[:p]

I also did the center area but kept theside grills stock, also filled in the washer holes.
http://www.audizine.com/gallery/data/500/2716shots_outside_008.jpg


Close up of the filled washer hole.
http://www.audizine.com/gallery/data/500/2716bumper_-_grill_1.jpg

mike-2ptzero
04-04-2007, 07:52 PM
I looked at the fibreglass as you mentioned... i found the bondo to be "easier" because i had experience with it.

The holes are very smooth and level, i do need to do some "fine touch ups" .. i guess paint will tell how good my work was. Thanks for the advice though mike, i did appreciate it

Only bad thing about bondo is that it can crack and pop out. This is why I went with the fiberglass since it can flex with the bumper skin while still giving it a little more stiffness in that area.

1.8TurboAudi
04-04-2007, 08:00 PM
sick man ..

onemoremile
04-04-2007, 08:50 PM
I use the fiberglass resin mix too. It's called kitty hair and looks like a puked up hair ball.

http://www.evercoat.com/imgs/products/Kitty%20Hair.jpg

I plan on doing the modded S4 bumper too. No headlight washer system or caps. RS4 style mesh painted with plasti-dip or powdercoated satin black. A set of Hella FF75 driving lights sunk deep into the corners. A black anodized intercooler hiding behind all of it. Should be kinda nice.

I was planning on modding the side grills over the weekend but it dropped from 73 to 27 overnight. Shorts and flips flops yesterday and icy roads today.

mike-2ptzero
04-04-2007, 08:56 PM
I use the fiberglass resin mix too. It's called kitty hair and looks like a puked up hair ball.

http://www.evercoat.com/imgs/products/Kitty%20Hair.jpg

I plan on doing the modded S4 bumper too. No headlight washer system or caps. RS4 style mesh painted with plasti-dip or powdercoated satin black. A set of Hella FF75 driving lights sunk deep into the corners. A black anodized intercooler hiding behind all of it. Should be kinda nice.

I was planning on modding the side grills over the weekend but it dropped from 73 to 27 overnight. Shorts and flips flops yesterday and icy roads today.

They actually make that? How weird. I didn't even know that when I made the stuff up by cutting and pulling apart the FG and then added the resin to make it into a ball.

seank
04-04-2007, 09:18 PM
best looking setup by far unless you got the cash to go real rs4 not the crappy rieger

kelticslob
04-04-2007, 09:24 PM
http://www.audizine.com/gallery/data/500/9139Picture_240.jpg

Winters are off now...

Euro
04-04-2007, 09:38 PM
Seen it done before...

I cant really tell if I like it or not. It seems sorta half ass, either get an RS4 or an S4... Maybe Im just to much of an OEM man. Its cool to be different.

Post more pictures if any one else has done this. [:)]

mike-2ptzero
04-04-2007, 10:49 PM
Seen it done before...

I cant really tell if I like it or not. It seems sorta half ass, either get an RS4 or an S4... Maybe Im just to much of an OEM man. Its cool to be different.

Post more pictures if any one else has done this. [:)]


Well the problem with the RS4 bumper is that it has less room for a fmic vs the S4 bumper. The S4 bumper just has a cleaner look too.

iwasawesome
04-04-2007, 10:58 PM
other issue is the rs4 doesn't fit right... even the best jobs i seen still have a bulge somewhere.
The s4 is nice, but i would like to see my FMIC. It looks kind of weird if you just have the centre open and the sides closed... so you could mesh the centre and leave the sides.. but that would look fvcked.. so you mesh them all :) hence the srs4 bumper.

It seems to be the best of both worlds. Looks good, fits better then rs4, not as cheap as the reiger.

Shifty
04-05-2007, 05:46 AM
To weigh in on the fiberglass/bondo discussion: if you're molding two pieces together - which it sounds like you are but I can't find the tech article - I would recommend Fusor 152 or Duramix products. These are two-part epoxies that will cure to plastic-like qualities, and because these are PPO repair products they're made to flex while remaining intact.

The advantage of using these products over fiberglass or filler is that the work time is decreased A LOT because you're not filing it down after every coat. Plus the epoxies are sandable in a matter of minutes. Duramix 4030's working window is 1 minute!! Also, I would strongly advaise against filler alone, as it will begin to split over time if it isn't used with FG or epoxy. The downside: the applicator gun is about $75, and a tube of material is around $50. Still, worth every penny.

onemoremile
04-05-2007, 06:52 AM
A plasticizing agent can be mixed with a bit of the kitty hair to keep it flexible. All you've really got to do is tell a body shop you're working on a few small repairs on a Corvette. They'll tell you how to mix it up so that it remains flexible enough to avoid cracking the paint. Marine stores are where I usually get my fiberglass supplies.

onemoremile
04-05-2007, 06:54 AM
They actually make that? How weird. I didn't even know that when I made the stuff up by cutting and pulling apart the FG and then added the resin to make it into a ball.

I used to pull apart chop strand mat and mix it up too. I was with a friend in a boat store telling him what a mess it makes when he holds up that can and says "why don't you just use this stuff?". I was floored. I had been mixing FG mat, resins, and thickening agents (West System has great thickeners) for years.

onemoremile
04-05-2007, 06:58 AM
Seen it done before...

I cant really tell if I like it or not. It seems sorta half ass, either get an RS4 or an S4... Maybe Im just to much of an OEM man. Its cool to be different.

Post more pictures if any one else has done this. [:)]

My personal opinion is that the modded bumper looks just as good for half the price. The S4 bumper is $600 with grills from the dealership. It fits perfectly right out of the box and doesn't have those ugly side grills. As Mike said, it also offers up a lot of room for an intercooler. It also seems less of a poser mod since it isn't really trying to look like an RS4.

Bic-Ball
04-05-2007, 07:34 AM
i like the look of this, but im not crazy about the mesh

onemoremile
04-05-2007, 07:40 AM
Winters are off now...

I took a peek at your gallery. It looks like you left the grills out and just smoothed out the areas they would mount to. That looks really good. I've seen it before but it looked a lot rougher. Nice job. [up]

mike-2ptzero
04-05-2007, 08:12 AM
To weigh in on the fiberglass/bondo discussion: if you're molding two pieces together - which it sounds like you are but I can't find the tech article - I would recommend Fusor 152 or Duramix products. These are two-part epoxies that will cure to plastic-like qualities, and because these are PPO repair products they're made to flex while remaining intact.

The advantage of using these products over fiberglass or filler is that the work time is decreased A LOT because you're not filing it down after every coat. Plus the epoxies are sandable in a matter of minutes. Duramix 4030's working window is 1 minute!! Also, I would strongly advaise against filler alone, as it will begin to split over time if it isn't used with FG or epoxy. The downside: the applicator gun is about $75, and a tube of material is around $50. Still, worth every penny.



With the RS4 mod to the S4 bumper it is just about filling in the hole left after removing the bar that is in the center.

onemoremile
04-05-2007, 08:15 AM
Yup. There are 6 spots that need glassing and they are all the size of a golf ball. 8 spots if you fill the washers.

mike-2ptzero
04-05-2007, 08:19 AM
I took a peek at your gallery. It looks like you left the grills out and just smoothed out the areas they would mount to. That looks really good. I've seen it before but it looked a lot rougher. Nice job. [up]

that or he put the grills in and filled it all it to make it look like 1 solid bumper. The reason I say that when the grills are removed the area between the side opening and center opening is very thin as you can see in this picture of my S4 bumper with none of the grills in place.

http://www.audizine.com/gallery/data/500/2716painted_bumper_on.jpg

His
http://www.audizine.com/gallery/data/500/9139Picture_241-med.jpg


This view it seems like the grill ring is there but just molded in
http://www.audizine.com/gallery/data/500/9139Picture_243-med.jpg

onemoremile
04-05-2007, 08:28 AM
Good point. The tops of the three openings line up differently without the inserts too.

EuroA4
04-05-2007, 08:44 AM
Are you all planning on using the real RS4 grill inserts cut up to fit....or trying to powdercoat the cheap HD stuff?

iwasawesome
04-05-2007, 10:47 AM
real stuff.. already ordered

kelticslob
04-05-2007, 11:33 AM
I took a peek at your gallery. It looks like you left the grills out and just smoothed out the areas they would mount to. That looks really good. I've seen it before but it looked a lot rougher. Nice job. [up]

Wish I could take credit for it. I bought it off of HeveyS4 who got a body shop to do it.

Thanks for the kind words nonetheless.