Hello I finally decided to make an account after looking and learning from all your guys progress for many years. To introduce myself I am from Edmonton, Alberta, Canada, and have owned my 87 GT V6 for about 5 years now.
Here is my first contribution to the forum

The brackets for the grill and lights have to be custom made depending on how you make your bumper as there is not too much room inside.
I used Sebring turn signals off of ebay. You can mount the lights and grill to the front metal support, or the bumper itself by fiberglassing brackets.

To start off I straight cut up and down on the sides, and perfectly level on the top


Secondly I constructed a rough shell using MDF and carfully measuring


Testing...


Filled it with foam


Shaved it to get the shape, cut out the center to how I wanted it


Duct tape for easier fiberglass removal later


One layer of fiberglass to get the rough structure I wanted


Poped it off - took awhile...


Testing again...


Fiberglassed it to the original and added more layers


Lots of bondo...


Pretty close


Doesn't droop like some others I have seen


Sanding and high fill priming








High fill primer


Rossa Red


Complete

[This message has been edited by DaytonTD (edited 12-06-2012).]

Nice !

Thanks for sharing. Would love to see more of the car and of your other work.

Welcome out of the shadows.

Wow! That's amazing work!

That copper coloured GT looks familiar. . . .

quote Originally posted by Dave E Bouy: That copper coloured GT looks familiar. . . .

It was candy orange, I was on the Fiero Calendar a few years ago maybe thats where. I think I may go back to a candy orange Ferrari though

welcome to the forum .that looks really nice ,do you do your own painting too?

Looks good!!! more more

quote Originally posted by wftb: welcome to the forum .that looks really nice ,do you do your own painting too?

Yes I do my own painting as well

Heres the rear, trying to find some old pictures of when I did the tail light panel for another how to thread

Really excellent craftmanship. Looks like it belongs. I especially like the way you kept the nose a bit more compact than the commercially available nose. It has far better proportions and doesn't have that awful forward extended look.

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" THE BLACK PARALYZER" -87GT 3800SC Series III engine, custom ZZP /Frozen Boost Intercooler setup, 3.4" Pulley, Powerlog manifold, Northstar TB, LS1 MAF, 3" Flotech Afterburner Exhaust, Autolite 104's, MSD wires, Custom CAI, 4T65eHD w. custom axles, HP Tuners VCM Suite.
"THE COLUSSUS"
87GT - ALL OUT 3.4L Turbocharged engine, Garrett Hybrid Turbo, MSD ign., modified TH125H
" ON THE LOOSE WITHOUT THE JUICE "

When I started scrolling through the pics with the duct tape and bondo, I thought to myself that it's gonna look like crap. It looks like a production piece that belongs there. Great work! I agree with Dennis as to proportions.

Car looks familiar. We sold our car (Her86GT) to a guy from Edmonton. Copper color similar to yours. but a little different. 3800S/C firebird dash. black trim.

Have you seen it?

Pete

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88 3800 turbo...10 sec Quarter Mile Member.

I've never seen a copper/orange Fiero in the city besides mine. Mine was burgundy when I did buy it though

quote Originally posted by PBJ: Car looks familiar. We sold our car (Her86GT) to a guy from Edmonton. Copper color similar to yours. but a little different. 3800S/C firebird dash. black trim. Have you seen it? Pete

Beautiful work!

How much of the 2-part foam did you use?

Which Bondo product, specifically?

Thanks!

Hey that's pretty cool. Another guy from Edmonton. If you have some time check us out on Facebook - Edmonton Fieros.

Very nice work. Looks good too. My only problem with the way you did it was using the stock flexible urathane bumper top. I would have just used it for part of the mold and made the whole thing one piece...all fiberglass. I think your going to find that the fiberglass will only stay on the urathane a short period of time before it starts breaking away. As one piece it would last till you crashed it. Remember 'bondo' spreaders are made out of similar material as the oem bumper. I dont even clean mine...I just let it harden, then all the bondo pops off cleanly for me to use it again. I do the same thing with fiberglass...bend the spreader a little and it all pop off clean. Again, I think you did an excellent job of constructing what you did from scratch...id just hate to see all the effort go to waste.

quote Originally posted by rogergarrison: id just hate to see all the effort go to waste.

Yup, I was wondering that also. It looks like it may crack in the future. Plus, if you had a mold, you can replace the part in the future if something happens... or sell copies.

Thanks guys for the advice, I did use alot more fiberglass than you can see, the thing weighs a ton. The outside original part only really provides the outside shape. It held for the whole year so far though

I used two part foam but then realized I didn't have enough so I just finished it with spray foam insulation, and for the "bondo" I actually mostly used Rage Gold, just a habit calling it Bondo lol

And for the Edmonton Fiero reply, I actually have been to two of the meetings. I just never seemed to be able to make it to any events last year, busy with work and fixing the car!

[This message has been edited by DaytonTD (edited 12-07-2012).]

quote Originally posted by rogergarrison: Very nice work. Looks good too. My only problem with the way you did it was using the stock flexible urathane bumper top. I would have just used it for part of the mold and made the whole thing one piece...all fiberglass. I think your going to find that the fiberglass will only stay on the urathane a short period of time before it starts breaking away. As one piece it would last till you crashed it. Remember 'bondo' spreaders are made out of similar material as the oem bumper. I dont even clean mine...I just let it harden, then all the bondo pops off cleanly for me to use it again. I do the same thing with fiberglass...bend the spreader a little and it all pop off clean. Again, I think you did an excellent job of constructing what you did from scratch...id just hate to see all the effort go to waste.

I was thinking the same thing...
At first I thought he was making a mold, but then I seen the finish paint
Theres allot of weight there; MDF is quite heavy. Also many different materials all bondo'ed together... Pull a mold of that nice-looking bumper and make a full fiberglass bumper before its too late Maybe offer them for sale!

[This message has been edited by ALJR (edited 12-07-2012).]

quote Originally posted by ALJR: Theres allot of weight there; MDF is quite heavy. Also many different materials all bondo'ed together.

He got rid of the MDF

That's a really nice looking car. Good work.

Thats a good idea, I was going to take it off and repaint it anyways since it got pretty beat up last summer from steep driveways . I have never made a mold before, if it's not too bad then maybe I will, that way I can make it all fiberglass as well. I may also do a rear end. Is there any threads on how to make a mold here?

quote Originally posted by ALJR: I was thinking the same thing... At first I thought he was making a mold, but then I seen the finish paint Theres allot of weight there; MDF is quite heavy. Also many different materials all bondo'ed together... Pull a mold of that nice-looking bumper and make a full fiberglass bumper before its too late Maybe offer them for sale!

[This message has been edited by DaytonTD (edited 12-07-2012).]

You already have the positive piece..All you need to do is wax it up good or apply release agent and lay fiberglass over it all to make a female mold. Put in some metal or wood braces as you go to keep its shape and your done. Then when you have a rigid female, all you have to do is put release agent inside it and lay fiberglass to make an exact duplicate of your positive finished one.

quote Originally posted by fourpoint9: He got rid of the MDF

oops..

Still wouldn't trust that bont between the plastic and fiberglass; it will seperate, just a matter of when...
Having a mold, even if not used right now, would save allot of extral work in the future if he had/wanted to make another...

And I agree with the others, the proportions of this bumper match the fiero very well. Only part of the car im not a fan of are the Ferrari badging...

[This message has been edited by ALJR (edited 12-08-2012).]

quote Originally posted by DaytonTD: Thats a good idea, I was going to take it off and repaint it anyways since it got pretty beat up last summer from steep driveways . I have never made a mold before, if it's not too bad then maybe I will, that way I can make it all fiberglass as well. I may also do a rear end. Is there any threads on how to make a mold here?

Nice job. I agree with the others. Surprised you have not seen problems yet.

Here are a couple build threads that others have done, but there are a number of them...
https://www.fiero.nl/forum/Forum1/HTML/087053.html
https://www.fiero.nl/forum/F.../HTML/000091-34.html
https://www.fiero.nl/forum/F...1/HTML/076365-4.html

Bob

You use to live in cold lake? I remember when you first signed up for edmonton fieros back a few years. Car sure has changed quite a bit. Are those PT cruiser rims? Nice work..

Hey whats wrong with my Fer-iero badging lol

Thanks guys I plan to make a mould maybe this christmas break, that way it will lighten it up a bit as well. Ways a ton right now...

No I never lived in Cold Lake, I have brought the car when it was orange to a few meetings though. And they're Boss aftermarket rims, not PT cruiser

How much does this actually cost you to make do you think? If you made a mold of it? And would you ever sell them?

[This message has been edited by mitchjl22 (edited 12-10-2012).]

I'm not really sure, I would have to add up the resin, fiberglass sheets, bondo if there is touch ups needed, and possibly accessories like mounts and what not if I did sell them. I'd tag a little bit on for my time as well, wouldn't be no $600 though. I'm guessing $300-350ish. I never really kept track of what went into it.

quote Originally posted by mitchjl22: How much does this actually cost you to make do you think? If you made a mold of it? And would you ever sell them?

quote Originally posted by DaytonTD: Hey whats wrong with my Fer-iero badging lol Thanks guys I plan to make a mould maybe this christmas break, that way it will lighten it up a bit as well. Ways a ton right now...

I had Ferrari badging on mine, but it was a replica. I always thought a stock body Fiero was a little too light in the front anyway. The extra weight would prob make it a lot better in rain and snow...but im guessing it never see either

Did you use a two part mix to create the foam?

What is it called?

Where can I get it in the states?

What does it cost?

Would it make more financial sense to just use spray in insulation like STUFF if I'm only doing a front fascia instead of a whole body?

Thanks,
Jonathan

Share some info on the rocker panels

I used two part foam initially, then I ran out and used spray foam. Spray foam is way cheaper and does the job. Two part is better for more precision shaping.
Not sure where you can get it in the states, I got it at a resin/plastic shop.

For the rocker panels I just cut them as you see them, then put stretchy fabric overtop the rocker panel and tucked it under the tab that was cut, then I pushed the tab down so it created a wall around and not a hollow spot then put resin on it and reinforced it with fiberglass.

if you do make a mold and start selling them let me know i would be interested...

+1 for the nice car and nice thread!

I like everything you did - it looks really good and I appreciate your effort to share with the fiero world. I would like to do something similar to what you did but have one question that is not resolved in my head. How did you bond the fiberglass to the flexible remaining fiero bumper cover parts?

Thanks & nice work!

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84 NB, 3800SC, E-25 Fuel, VS Cam, 3.2 Pulley, 4T65E-HD, HP Tuners, AEM Wideband, Regal GS Gauges, S-10 Brake Booster. 12.53 at 106.5 1/4 mile

One word from me to you..........,

INSPIRING!

Your design is not exaggerated but elegant, it makes the car look more solid. It looks like a true sports car, but with muscle. Nicely done!!!

Roger has always given great advice. I have a spare front end that I think I will follow his advice with and make a female mold and then attempt to emulate what you have done. Again, INSPIRING!

Thanks for sharing.

Thanks guys for the compliments!

quote Originally posted by DimeMachine: I like everything you did - it looks really good and I appreciate your effort to share with the fiero world. I would like to do something similar to what you did but have one question that is not resolved in my head. How did you bond the fiberglass to the flexible remaining fiero bumper cover parts? Thanks & nice work!

I just roughed up the original fiero bumper where I could and used tons of resin and fiberglass to attach it to the most area possible, and it seems to be holding good. I will however eventually make a complete fiberglass bumper as others have suggested.