I came across the bumpers in the tidy up, and I remembered that I wanted to change the way they mounted to the body. When I first bought the car, the bumpers were full of expanding foam and rotten wood. They were also fixed to the car using wood screws. This simply would not do, so I thought about different ways to mount the bumpers in a more stealthy and more secure way. As I had removed all the foam and old wood, the bumpers are now much lighter and of course hollow. My solution is quite simple: make a u-shaped bracket at each mounting point out of sheet steel, weld a captive nut on the inside, fibreglass the u-bracket to the inside of the bumper, then drill a hole in the bodywork to bolt the bumper on from inside the engine bay/boot.
So it was out with the old CAD (cardboard-aided design) - I mocked up the brackets then re-made them in steel. I then drilled holes for the bolts and was getting ready to weld them up. Then the welder wouldn't feed the wire through, so I gave up and went inside.
CAD templates made...
...and replicated in steel.
Holes drilled and nuts ready for welding, once I can get the poxy welder to work...
