Covid upgrades - R400 bumper finished [emoji1688]

[Sampson]

Hey guys! Where I live in Australia we’re currently under a second lockdown

So, I’ve finally gotten around to plastic welding on the bottom of the R400 golf front bumper. Never done any body work before but took my time (it’s all I got at the moment)

Next up is new wheels (2020 Audi RS6) fitting the TRC side and rear splitters and a custom exhaust set up.

Here are some snaps (haven’t finished the cut back of the clear or the black and acid green grill)







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[petrev]

Nice.

Like your style, not seen any other 400 mods (that I can recall !)

Great

[Giddy]

I haven't seen this done before either. Good work!

[Ryzar1]

That’s very nice mate I live in Melbourne so my caddy work has come to a halt I’ve got the splitter ready to put on my front end with new fog lights and badgeless grille and a r32 style rear bumper
That needs painting


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[Sampson]

Thanks guys, I hadn’t seen it done before either so that was the motivation to do it

Think what I’m doing with the rear has never been done before either so I’ll post up here when it’s done.

Sounds sick Ryzar1, I’m just down bayside very interested to see your caddy when you’ve fitted everything


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[Ryzar1]

For sure sounds good


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[hef355]

Thats really nice, unique and different mate, nice detail on the colours too well done indeed


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[Sampson]

Thats really nice, unique and different mate, nice detail on the colours too well done indeed


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Cheers Hef Been a huge fan of your caddy ever since I discovered this forum, great inspiration.


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[hef355]

@Sampson ahhh thank you for your kind words buddy! Quite surreal that this forum brings people and ideas together globally! Keep up the fine work my friend


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[nathansmith123]

That's really nice. Do you have any pictures of the process? I'm keen to see how folk go around grafting bumpers but havent been able to find any information

[Sampson]

That's really nice. Do you have any pictures of the process? I'm keen to see how folk go around grafting bumpers but havent been able to find any information

Yeah no worries, here’s a list of things I recommend using/what you’ll need.

Laser level
Multitool (both cutting and sanding attachments)
Butane Plastic welder with polypropylene rods (PP)
A gas mask with correct filter
4 inch grinder with 40 grit flap disc (made sanding back plastic welding simple)
Flexible plastic bumper filler (I used isopon)
Suitable primer

A couple of small tips*

When cutting your bars, don’t shoot for the perfect cut straight away, leave more to trim away. The last thing you want is have to plastic weld a sheet you’ve cut off back on.

Once cut, I found it easiest to put the OE bumper back on the car and match up the new lower half there by chocking it up to the correct height, using the laser to find centre of both bars and putting your first weld there as a tack and moving from there.

When plastic welding, for a strong weld, use a box cutter to make the edges more of a V i.e:

Top. \/
Bottom. /\

Doesn’t need to be that dramatic of an angle, just trim the edges so it’s not a 90 degree edge. The aim is to weld the two centre points together as a surface weld won’t be strong. I also dragged more plastic from above and below to overlap. Weld front and back


* because of the unique shape of the r400 bumper I didn’t cut my bumper straight, but in hindsight, I could of.


Plastic welding smoothed off


Flexible filler in


Primed

*keep in mind there was a lot of sanding between the two last photos, get a decent powered lamp to look for imperfections, for the minor stuff, I used a good quality car body filler. 110% use majority of the flexible plastic filler over the plastic welding though.

Most importantly, take your time. If you’re getting frustrated it’s time for a break

Good luck


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[Sampson]

That's really nice. Do you have any pictures of the process? I'm keen to see how folk go around grafting bumpers but havent been able to find any information

Oh! And just a side note, if doing the R400 bumper the wheel arches are an absolute prick but not impossible, if going that route send me a DM and I’ll walk you through what I did, just don’t have any pictures.

It’s also very important when cutting your OE bar to KEEP YOUR WHEEL ARCHES! Don’t cut them off, run a cut down before you get to them.


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[gtiwolf]

Looks cool mate good work and cant wait to see the rear

[nathansmith123]

That's really informative, thanks!

[Pritchard182]

Lovely front end