by AusRs » Mon Apr 13, 2009 7:06 am
this is the way i would approach that repair
make an on car mold
do some sticking together with urethane (windscreen stuff)
do some plastic filler work on the car to make it as smooth as possible
get some mold release wax and wax it several times (so the glass does not stick to it ) make it as many as you want BUT 5 minimum
get some chopped strand fibreglass (heavy stuff )matting get some resin and hardener
read a little about how to mix the resin as it can go off a little fast sometimes
split the matting in 1/2 (you will know what i mean when you see the matting ) to make it thinner and lighter
then just attach the matting to the waxed areas ,build it up to maybe 4 layers of glass (ad some rolled newspaper or cardboard over the last layer ,folded to ad stiffness ),let it go off for a day or so THEN remove the part from the car
i would presume that the mold will need some reverse curves on it (impossible to remove from mold SO it has to be in 2 sections ) get some plywood and make a join at the corner (2 pieces so they can be bolted together (and unbolted to take apart ) then prepare the back surface (wax etc ) then repeat the wax etc then glass that
when its all nicely dried out split the mold and remove both parts of the oem bumper
does t hat make any sense to you ??????????????
in all honesty it is NOT hard to do ,,,,,,,,,,,,,,its just the cost involved to make a 1 off part
to produce the part off of the mold is slightly different BUT no more difficult !