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Guides - Modifying Nova GSi front bumper
DISCLAIMER: The information in these documents are a collection from experience (friends or myself), magazine articles, mailing
lists and internet web sites etc. So don't take these as 100% correct gospel, hence I don't take any responsibility for any of these
guides.
Difficulty Rating: 4/5 - A bit fiddly - but worth it.
Download printable Adobe Acrobat file (540K) Created: 16 Dec 2000
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Click on any of the pics for This is a step-by-step guide on modifying a Nova GSi front bumper so
a larger view. that the middle slat is cut away and replaced with a mesh grille. This
particular guide shows how the air duct is 'boxed in' so that it gives
depth, other mods simply place a big piece of mesh flush with the
surface with the bumper. Because of the boxing in nature, this
modification is difficult to do, very fiddly in places and may take
several weeks to complete (it took me a month to do, as it was the
time I've ever done this sort of thing). But by following this guide, you
should be aware of any problems and be able to do the job much
Before... quicker.
You can buy this modification already done, fiberglass copy front
bumper from (as seen in many car
Kingdom Developments
magazines). The difference is that the mesh is flush with the rest of
the bumper.
You will need patience, lots of pug (filler), fiberglass and lots of
sanding down and filling back up tasks. I chose to do it this way
because I've never seen it done before and it is unique, even though I
...and after.
have seen similar, if not identical looking bumpers at recent car shows
(Doh!). This modification also retains the use of the towing eye flap,
that it can be removed without damaging the fiberglass/filler, and your
work :)
PARTS
Nova GSi bumper Hack saw Pad saw Pug (filler)
Fiberglass Kit Stanley knife Permanent Marker Masking Tape
Mesh Metal cutters Spray primmer paint Sanding paper
Glue/Bonding Sanding block File Strong tape
COST
The part number for a new GSi bumper is
New Vauxhall Nova GSi front bumper Ł100
90443248. That is the plastic bumper only
Mesh (stretched diamond shape) 1x1.5m B&Q Ł18
(no carriage bar of fixings etc.). Try and
get galvanized steel mesh as this is
Gray plastic primer spray paint (2 cans) Ł5 ea
protected from corrosion.
Just before you start, make sure you note the following:
If you've got the Haynes manual for your car, have this is front of you. You'll need it on how to
remove the front bumper if you have to (either that or buy one).
Buy various grits of sand paper, 100 is rough, 1000 is smooth, you may use water to make
the job easier. Use 200 grit for first time sanding down, then once it starts to get smooth, use
400 grit. Once all the bad holes and cracks have been filed in, start the very smooth stage of
sanding down with 600-800 grit.
To bond on plastic, I used Adhesive, which are two compounds mixed together. Or use Silk-
Topbuzz Web Site - Guides - Modifying Nova GSi front bumper @ www.topbuzz.co.uk Page 2 of 6
o-flex or Tiger Seal that body shops use. Either way, wait 24 hours to dry before continuing.
Try and purchase galvanized steel mesh for the air duct, as this has good prevention
properties against corrosion. Use Enamel paint on the metal mesh when spraying.
If painting a new GSi bumper (like what is shown in this guide), spray several layers of plastic
primer on. This will show any imperfections missed in the sanding process.
When the bumper is placed back on the car, it may be beneficial to paint the front valence
behind the air duct a darker colour (i.e. black). Depending on how dense the mesh is, it may
not seem think enough and you will see the valence behind it.
OK, got all the above? Then follow the steps below (remember to click on the pics for a bigger view):
Step 1 Step 2 Step 3
This is what a brand new front Looking from the back, mark OK you've got all the tools and
Nova GSi bumper looks like, where you want to cut. Use a parts, now to make the first cut.
NOTE: it won't be staying like permanent marker and masking Work from inside the bumper
this for long. The idea is to cut tape. In this picture I'm keeping and chop off all the thin plastic
out the middle slat making a the side wall and lower ledge, legs off the top lip and middle
larger air duct. so I'll cut right on the edge of it. slat.
Step 4 Step 5 Step 6
Use the pad saw to cut the first Do the same on the towing eye
Now with the plastic legs and
side wall. Remember to keep to cover. This piece of plastic is
side wall cut, there is one final
the right of this as you can held into place by the two loops
cut along the length to separate
always file off the plastic you snapping into the bumper. By
it from the lower lip spoiler.
don't want. As this was a new cutting along the side wall, one
You'll need to use the pad saw
bumper the plastic was easy to of the loops will be chopped off.
to make a start on the cut, after
cut. Cut all the way down till it Fortunately one loop is still able
that use the hack saw.
meets the second lip. to hold the cover in place.
Step 7 Step 8 Step 9
Turn the bumper over again to
Use the hacksaw all away along Now step back and see what get at the back. Use a Stanley
the dip between the top and you've done. There's no turning knife and cut along the line you
lower lip spoiler. Once the cut is back now. You're 50% away made with the pen. It's very
Topbuzz Web Site - Guides - Modifying Nova GSi front bumper @ www.topbuzz.co.uk Page 3 of 6
complete, remove the strip of from finishing the cutting difficult to make a cut, not
plastic, but don't throw it away! sequence. All there is to do now enough room yet to use the pad
It will come in handy later on. is to chop part of the lower lip saw. This is to retain the depth
spoiler off. of the recess.
Step 10 Step 11 Step 12
Using the hack saw, cut along Take another step back and see
Once you've done enough
the edge until you meet the what is left. Both the spoiler lips
cutting with the Stanley knife,
same spot on the other end. are gone now. All the major
use the pad saw to cut along
Again you'll need to use the pad cutting of the bumper is over.
length of the lower lip spoiler
saw and Stanley knife to finish Use a file or sand paper to
and then use the hack saw to
off the job. Once is cut, remove remove swarf on the surfaces
finish.
the low lip spoiler. that have been cut.
Step 13 Step 14 Step 15
All that is left is the side wall and Before doing any filling, remove
the bottom half of the lower all the plastic swarf off the
With the middle slat cut out, cut
spoiler lip. The next job is to do bumper. The easiest method I
along the line as shown. You
a lot of filling to get a 'boxed in' found was to run the Stanley
need this in a few seconds, as
shape. This is to give the air knife along the edge. With older
you need this part as flat as
duct depth and so the mesh bumpers (i.e. second hand
possible.
grille won't be right at the front items) the plastic might be a bit
but further in. stiffer.
Step 16 Step 17 Step 18
Place the middle slat along the
The middle slat should be firmly
top of the cut out air duct. You'll With the middle slat along the
glued in. You may have to trim it
needed to wedge it in place (I top, put lots of glue between the
down to size (i.e. it may be too
used some bamboo sticks). mating faces, and again wedge
deep). The gaps in the corner
Note: it is not long enough to the middle slat in along the top
and what is left of the side wall
cover all of the top, so place it (as shown). Leave for 24 hours
need to be filled in (to give it the
away from the towing eye cover to dry.
'boxed in' shape).
(i.e. there will be a gap).
Topbuzz Web Site - Guides - Modifying Nova GSi front bumper @ www.topbuzz.co.uk Page 4 of 6
Step 19 Step 20 Step 21
On the side wall, trim it down There still will be some plastic
enough so that the 'boxed' in left over, cut a small bit off to Place the small bit of plastic
shape is level all the way round. plug up the gap in the side wall against the gap in the side wall,
Otherwise when the mesh is (as shown in the next step). and adjust as necessary. When
fitted, it appears to slope (do the Bend the plastic near the edge complete, put some glue on the
same to the towing eye flap as to that it follows the curvature of mating surfaces.
well). the wall.
Step 22 Step 23 Step 24
From the small bits of plastic
The towing eye flap is where it
left, cut a thin strip and bend it
starts to get difficult. I want to
You will again need to leave this at right angles. Glue this onto
keep the towing eye, so that I
for 24hrs for it to set, put the back of the towing eye flap
can remove it in the future.
something on them that will hold as shown. Place masking tape
Hence I can't fill in the side wall
the piece together, i.e. a G to hold the plastic in place and
gap as before. So a frame work
clamp etc. also to stop it gluing to the
is required so that the side is
wrong surface. Again wait 24
split.
hours for it to dry.
Step 25 Step 26 Step 27
Yet again using the left over bits
of plastic, cut a small piece so With the gap bridged in and the
Use fiberglass on the back to fill
that it bridges the gap on the glue fully dry, you should be
in the hole, or rather give it
towing eye flap (as shown). able to remove the towing eye
some backing.
Again glue this into place and with no problems.
allow to dry.
Step 28 Step 29 Step 30
Topbuzz Web Site - Guides - Modifying Nova GSi front bumper @ www.topbuzz.co.uk Page 5 of 6
Use fiberglass on the other side While the fiberglass is out, start Carry on with the filler all along
wall to make the wall complete. filling in the small gaps around the top part of the wall, as this
Again allow to dry before the rest of the air duct that you can be sanded down at a latter
working on it. have made with pug. date to make it smooth.
Step 31 Step 32 Step 33
Place a thin bit of plastic in
And again with the filler, pug up With the towing eye back on the between the gap so that you
the gaps in the towing eye flap bumper, use enough filler on the can carry on with the filler
so that the side wall becomes side wall so that they don't without fear of bonding them
solid. become stuck together. together (I used the lid of an ice
cream tub, which is very thin).
Step 34 Step 35 Step 36
Once removed, you can start
With the plastic separator in Do the same on the other facing
sanding down the pug so that
place, pug up the wall as much wall, as this is much easier to
the wall becomes uniform (use
as possible. Once the pug has do. Again use 200 grit paper to
you artistic flair here and make it
dried, carefully remove the remove any large lumps and
curvy as you want) Use 200 grit
plastic separator. This should be bumps. Add more pug as
to remove most unwanted
possible without the pug required to get the correct
bumps and lumps (using water
cracking. shape.
helps).
Step 37 Step 38 Step 39
Once all the filling and sanding
With basic filling done, the air is complete, clean the surface
Topbuzz Web Site - Guides - Modifying Nova GSi front bumper @ www.topbuzz.co.uk Page 6 of 6
duct should look like this. from dirt and dust with white
With some mesh (try and get
NOTE: this is a long process of sprit. Allow to dry (evaporate
galvanized), construct a 'tray'
filling, sanding, filling, sanding away). Spray the plastic
shape out of mesh. Make the
again, finding more air holes primmer with thin coats, using a
wings on each side about 3cm
and bubbles etc, then do some even spray right across the
deep, and fold these round the
more filling....the list goes on. surface. Allow 5 min between
side walls.
each coat to dry.
Step 40 Step 41
Bond on the mesh and squash
Once the mesh is cut out and on the mesh wings so it holds it
ready to go on, spray it the on. You may have to put some
colour you want, in my case I strong tape in place. Allow at
sprayed it with Black Enamel least 24hrs to dry. Wipe away
paint. Which also helps it stop any excess with white sprit. Put
rusting as it coats it. the front bumper back on the
car...and job done :).
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