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View Full Version : S4 bumper modification - suggestions (Updates on Progress)



aytheory
08-03-2007, 09:40 PM
This is what I plan on doing - the yellow spray paint is what I am going to cut with a dremel and sand to a smooth surface.

You notice that the back has some bondo - i notice a lot of these bumpers have weak spots in these areas - so i decided to use bondo as a reinforcement

The areas then will install expanded mesh as grills

My vote is here

1. I should leave a piece of the license plate holder so just trim the sides of the middle part - so I can put a license plate (like I pictured it)
2. Just shave the whole thing off - and worrie about the plate holder later
3. Leave it all alone and don't cut anything out of the center

Remember I live in CA - cops give you hell for not having a front plate.

http://www.showyourmedia.com/files/1186202146.JPG

http://www.showyourmedia.com/files/1186202179.JPG

http://www.showyourmedia.com/files/1186202240.JPG

btw thank Mike H.

StreetUrchin
08-04-2007, 12:20 AM
Off topic but do I see a bag of "erotica" in the background...?

aytheory
08-04-2007, 12:31 AM
aahahha good eye but nooooooo - porn tapes are so 1990s - unless your into the classics - but all online these days thats what the internet was made for.

aytheory
08-04-2007, 12:32 AM
also never mind - found out I can't cut anything because I would have to cut into the rebar. So I am leaving it stock and I was wondering how i fill in those holes where the plate goes.

A4 Effort
08-04-2007, 04:04 AM
Why don't you just get an s4 filler plate?

fred2ka4
08-04-2007, 07:08 AM
It looks like you were going to do the RS4 mod ......

mike-2ptzero
08-04-2007, 08:23 AM
Rebar is not all that hard to cut with a sawzall. BTW will you be putting a fmic behind the bumper?


If you plan on just leaving the center like it is you can just buy a S4 plate cover then mount your plate to that.

aytheory
08-04-2007, 08:45 AM
would cutting the rebar affect its structural integrity - I would like to get it as open as possible. Already have a fmic behind it - evoms one. Also i put bondo on the hole and the top part of the license plate cover - and going to use JB weild for the side cut because it flexes more and want to use something stronger as a filler.

Also how would I fill in the headlight washers never used them anyways only gets the car more dirty or should I leave that to the body shop that is painting it.

mike-2ptzero
08-04-2007, 12:16 PM
would cutting the rebar affect its structural integrity - I would like to get it as open as possible. Already have a fmic behind it - evoms one. Also i put bondo on the hole and the top part of the license plate cover - and going to use JB weild for the side cut because it flexes more and want to use something stronger as a filler.

Also how would I fill in the headlight washers never used them anyways only gets the car more dirty or should I leave that to the body shop that is painting it.

You could cut it line mine, I still have part of the front and all of the top section of the rebar in that lic plate area. I also left a small section of the rebar showing so I could mount a euro plate, this way you could also mount a CA plate.

http://www.audizine.com/gallery/data/500/2716headlight_inlet_009.jpg

The rebar section where I mount my euro plate is covered with blue painters tape.


It is easy to fill the headlight washer holes. I am pretty sure the body shop could do it with the rest of the work that you plan on having them do. I filled mine in on the S4 bumper pictured above.

onemoremile
08-04-2007, 02:56 PM
Filled mine too. The filler plate needs some filling and painting too.

http://i23.photobucket.com/albums/b397/onemoremile/IMG_4564.jpg

aytheory
08-04-2007, 02:56 PM
what did you use

onemoremile
08-04-2007, 03:15 PM
You can either have the body shop do it or use a fiberglass repair kit.

mike-2ptzero
08-04-2007, 03:19 PM
what did you use

To fill the sprayer holes here is what you can do.


1.Cut out 2 pieces using plastic, lexan or plexi-glass.
2. Put a screw in the very center of each.
3. Spread epoxy on one at a time and place them into the hole so that they glue in fron the other side, you can hold them inn place with the screw till it has tacked up enough or till it is dry.
4. Once they are dry remove the screw and fill in the area with a product called "kitty hair" which is a body filler with short strands of fiberglass. You can also make this yourself like I did by cutting fiberglass into short strands then mixing it in with a fiberglass resin. It also comes in handy to fill in the spots where the center bar was cut and to make those spots in the bumper stronger by adding some oto the back of the down sections next to the center grill area.

http://www.sherwin-automotive.com/images/products/evercoat_FE868.jpg

urS4
08-04-2007, 04:00 PM
This is what I did.

http://www.audizine.com/gallery/data/500/15349A4-1.jpg

I bought an S4 license filler with holes that was already black. I mounted the plate to the filler and I think I like the results.

Hap, wit dakine filler not from Evahboost, Maguire

aytheory
08-04-2007, 05:31 PM
To fill the sprayer holes here is what you can do.


1.Cut out 2 pieces using plastic, lexan or plexi-glass.
2. Put a screw in the very center of each.
3. Spread epoxy on one at a time and place them into the hole so that they glue in fron the other side, you can hold them inn place with the screw till it has tacked up enough or till it is dry.
4. Once they are dry remove the screw and fill in the area with a product called "kitty hair" which is a body filler with short strands of fiberglass. You can also make this yourself like I did by cutting fiberglass into short strands then mixing it in with a fiberglass resin. It also comes in handy to fill in the spots where the center bar was cut and to make those spots in the bumper stronger by adding some oto the back of the down sections next to the center grill area.

http://www.sherwin-automotive.com/images/products/evercoat_FE868.jpg

bwhaha thanks - kitty hair

aytheory
08-04-2007, 09:13 PM
Today did a little of cutting and trimming of the bumper.
Did some grille work.

Decided to not cut rebar - no tools just a dremel for cutting - getting S4 cover plate and sealing those cuts on the plate back up

Tomorrow - I am thinking about sanding it myself - anyone know where I can pick up a cover plate

Not sure if i should use a circular sander or a palm one
going with 400 grit and down to 200 before i give it to the body shop for paint

as you can see that under the red there is yellow - so the last layer wasn't removed.

http://www.showyourmedia.com/files/1186287040.JPG
http://www.showyourmedia.com/files/1186287059.JPG
http://www.showyourmedia.com/files/1186287089.JPG

onemoremile
08-05-2007, 06:33 AM
I put a request in my sig that said I was looking for an S4 filler plate. I got several replies ranging from 15 to 55 shipped. I got the $15 one.


So it looks like you aren't going to use the side grill inserts?

mike-2ptzero
08-05-2007, 08:29 AM
I had a plate filler that I bought from someone, but it turned out to have a few broken clips which the seller never told me about. Same seller sold me "grills" but turned out to be just the sections he cut out when doing the RS4 grill mod.

I can check to see if I still have the filler plate but I most likely threw it out when cleaning out one of my spare rooms.

Starting
08-05-2007, 09:36 AM
aytheory: you might not want to sand the bumper. As long as the paint is in good condition; meaning no peeling or cracking, they will probably just paint over that top coat. Also you wouldn't start with 400 and then go to 200. That isn't the way sanding works.

I didn't really read what you are trying to shave. If you end up not shaving anything they probably won't bother with a primer, and may not end up bothering with a sealer. If they don't spray a sealer or primer then it will be important how the bumper is prepped and what the final sanding grit is. Also If you begin sanding and start sanding all the way to the plastic on alot of the bumper, the bumper will have to be prepped a different way. I did a writeup on painting a bumper that might still be in the DIY section, but it may have been lost in the crash.

aytheory
08-05-2007, 10:52 AM
Yah - not using any of the stock side grille - never came with them and not planning to go hunt them down takes too much time - and as Mike had dealt with some shady sellers.

Starting - the bumper since it has been painted over - suffers a common problem of repainting is that the peeling starts from the inside and sometimes spreads out - parts (back of the bumper) that were not given full attention because they are not in plain view.

As for the sanding - i got that info from stupid websites on how to paint old cars made from steel.

The bumper need some spot treatment - other then that the paint is fine.

This will be interesting if they paint it over - I will have the thickest paint and road chips could show up as yellow and red on a blue car.

I will not sand now after hearing your advice starting - I'll just let the body shop worry about that stuff.

I think I will also just tell the body shop to fill in parts of the license plate cover holes don't want to go hunt down a S4 plate filler.

I did find this

https://www.mattman-enterprises.com/cart.php?einstein_jump=view::item&item_id=550

Think i can get away with this in California - with my real plate numbers on it.

I know it is a bit of a stretch.

mike-2ptzero
08-05-2007, 01:37 PM
You could just get the S4 plate filler from the dealer if you want a new one, but I do still have the one I bought from someone sitting here at my house.

aytheory
08-05-2007, 02:08 PM
Can I get the filler plate please --------

Planing to get it painted with the rest and mount my license plate and mount that came on the A4 bumper on top of the filler.

mike-2ptzero
08-05-2007, 02:12 PM
Can I get the filler plate please --------

Planing to get it painted with the rest and mount my license plate and mount that came on the A4 bumper on top of the filler.

Sure. I will be back up at the dealership in downey again on monday around 11 since I have to stop off at a dealer in San Juan Cap first. Give me a call to let me know where you want to meet me.