Making a fibreglass bumper is not a difficult process if you have an old bumper or bumper mould to use when making the bumper. You need some kind of mould or shaper, otherwise the bumper will not fit snugly into the car or motorcycle. The sturdiest material to use for a fibreglass bumper is carbon fibreglass. Layer this with traditional fibreglass sheets for a strong bumper that will last for years.
- Skill level:
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Things you need
- Original fender or bumper mould
- Degreasing cleanser
- Soft cloths
- Gel coat
- Carbon fibreglass
- Fibreglass sheeting
- Work gloves
- Fibreglass resin
- Metal roller
- Rubber mallet
Clean the original bumper with a degreasing cleanser to remove all dirt and oil. Spray the mould with a gel coat to protect the surface and to make it easier to remove the fibreglass bumper when finished. Allow the gel coat to dry for 24 hours.
Put on the work gloves. Cut the carbon fibreglass into small strips. Lay a layer of fibreglass over the bumper mould.
Add a layer of resin to the fibreglass. Try not to overlap the edges of the bumper or mould with resin. You would have to eliminate any excess material later, which can be a time-consuming process.
Saturate the fibreglass with the resin. Apply a second layer of fibreglass, and another layer of resin. Continue building up fibreglass and resin layers until you have five layers of fibreglass. Alternate a carbon layer with a fibreglass layer, ending with a carbon layer.
Roll the metal roller over the fibreglass to eliminate air pockets. Allow the fibreglass to dry for 12 hours. Add one final coat of resin to fill in the holes and remove the rough texture of the fibreglass sheeting. Allow this resin to cure for 24 hours.
Remove the bumper from the mould. You may have to tap gently with a rubber mallet on the sides of the bumper to release it.
Note where the mounting holes sit on the original bumper, and drill a hole into the new bumper in the same spots. Drill carefully, so that you do not crack the fibreglass resin.
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