Since
the last update, we have had the opportunity to explore using alternative
reinforcement materials and, more importantly, a completely different resin chemistry
(vinyl ester) in the vacuum infusion molding process we use to produce our
composite rear bumper. After a number of
scout procedures, the end result was molding characteristics I simply didn’t
like and would not commit to trying any further. So, not much to report on that front as it’s
not got much to do with making a bumper!
Suffice it to say that in any future endeavor, we will stick to our
first low viscosity epoxy resin choice and basic combination of reinforcement fabrics and not
look back!
With
that, the update is rather anticlimactic.
After extensive consideration, we have decided to stay with our 0.137”
bumper molding as it is visually almost perfect and will allow greater ease in
mounting than a thicker molded copy. Now
the focus will be shifted to developing a robust mount system that can be
bonded into the bumper shell with panel bonding adhesive.
Work
has begun to craft an aluminum mount that will add good structure to the bumper
and provide a solid mounting base that can be easily bolted to the stock
mounting locations with a full range of adjustability to allow optimum fit. At the same time, this strategy will allow
the bumper to be fit to the body with simple gap shims that will allow the
bumper to be quickly and easily placed in position and aligned on the mounts
with perfect body gaps maintained and little to no induced stress into the part
while the panel adhesive cures. Once we’re
on top of this series of details, the remainder of bumper work should be
relatively conventional insofar as confirming fit and edge finish followed by
preparing the part for primer. Feels
good!
In
the meantime, work will continue on completing the final bumper trimming,
taillight bezel and bucket prep and fitting, backup light housing modification
and fitting and final gapping of the doors with the hope of Spring weather
allowing a deep-dive into the cleaning and metal prep work on the front sheet
metal. Feels like it’s getting traction
again…….
