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Discussion Starter · #1 ·
I spent all evening in the garage with the Dremel cutting the Front bumper to fit my Evo 2 with the big intercooler fitted.

My initial idea is to buy a 2nd hand aftermarket bumper for it to allow me to use the larger intercooler for my mahoosive turbo conversion.

2 broken cutting discs, about a metre of masking tape and some scrapes and grazes later, the std bumper now fits ok. The only down side is that the central "hole" isn't quite as deep or as tall as the new intercooler so I got to thinking about it and if I can modify the lower edge of the central aperture, I can maximise airflow to the whole intercooler. I want to do a proper job so was thinking about plastic welding as a way to get a nicer finish to the bumper rather than just cutting it. I would basically cut and shut the bottom edge by moving it down and fit the Evo 3 splitter .I'll probably drill some holes along the top and fit a small no. plate as the metal plate/bracket behind areas of the bumper is needed for strength and I can't remove it all as thats where the brackets mount to.

Heres what it looks like with the std intercooler:


would plastic welding work?
 

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Discussion Starter · #2 ·
Heres a rough chopped image showing the resized central hole, i put some holes along the top of where the no.plate currently sits for effect, If I go this route I'll obviously put them all the way across.

 

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you will find this a bit of a mission my friend. looking at your pics the prob you will have is that you will have very little plastic left to weld too and very little room to get into the area you want to weld as most of the hard work is done from behind. if you want it to look the best you can then i would cut the bumper as neatly and as precise as you can and want, then get the fibre glass mat and resin out to make the lower edge as neat as poss, but this is also as messy as roadkill on the m25. once happy with the next step of your picasso sculpture, get the filler out and do the final tidy up. then its ready for prime and paint.

sprayteck.
 

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Discussion Starter · #6 ·
****-holes

I know the holes don't look too hot in my shoddy picture but if they were a bit larger i think they would look ok in the flesh.

as for the intercooler, it came with the turbo kit from Japan, God bless Ebay.
 
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