Managed to pick up a spare 406 bumper for £10 on ebay. Perfect starting point as i have never modded a bumper before.
Using shape of the bumper i traced out the new lip using cardboard below the bumper. Made mounting holes easier to work out.
I then trimmed the template so I could make sure it fitted the piece of wood I had to make the lower lip.
The base of the bumper was then cut from a piece of hardboard. This meant the bumper could be affixed to it quite easily.
Next I had to start to fill the lip with expanding foam, this would help the filling process later.
The foam was trimmed and shaped to make the lip more aero dynamic, before I could apply any filler.
Next a set of supports were added, to help remove the down force on the front lip of the bumper.
I shaped some cardboard and made the side bumper vents filling them again with expanding foam.
With the foam dry I then started cutting out the shape of the side vents to the contours of the bumper.
I then began appling plastic filler onto the expanding foam to give the lip a bit more rigidty.
Sanding and priming the middle section is starting to take shape. One corner nearly done.
I'd had enough of this bumper it was taking too long, so I settled on its condition and it was time for spray
Spray job completed and the bumper is re-assembled ready to be fitted back on the car.. with a couple of extras
Headlights out to fit a bumper!..fingers crossed all is good. I even fitted the movie car french number plate.
After much jiggling around.. its fitted.. a few cracks already to address but its on and solid. Yay!
Creating the roof scoops was fun, I started with expanding foam by filling a box with the stuff. I then cut out the shape of the roof vent once dried.
Once I had cut the shape, I coated the foam with plastic filler to give it some rigidity. It also added a little bit of weight to it..
I added a primer coat to help with the smoothing of the filler. As you can see the surface was very rough and needed filling..
A coouple of hours with the sander, the vent is starting to take shape still a few rough sides to sort but the vent is getting close to end product..
Primered again.. got to smooth inner rim for grills.. so more filling to go yet.. but looking like a roof vent more and more.
£20 and a tank of fuel to get this.
Priming the main section of the spoiler.
I cut a new set of end caps to the size of the movie car.!
The middle section was painted in white..
Had to make a custom mount but its now fitted to the boot..