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Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

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Slownrusty
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Joined: Wed Apr 24, 2019 2:22 pm
Location: Houston, TX

Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

Post by Slownrusty » Sun Sep 13, 2020 2:17 pm

My car is a US-Spec '86 CSi Manual.

I finally completed the fabrication of aluminum mounts to convert the bumpers from the heavy, obtrusive US-Spec ones to the Euro. These mounts I made are 100% bolt-on using all the factory mounting points on the chassis, so no grinding, drilling or welding required on the car. "Let the parts fit the car, do let the car fit the parts" <- is my moto.

I hope you enjoy the pictures, the YouTube video and they are useful for future owners.

My car when I first bought it:
Image

Mocking up the Euro bumper, which I was lucky able to find used here locally in Houston. Its in good shape just needs a bit of TLC, media blasting and paint. I have all the chrome and rubber as well all in decent shape.
Image

Getting to work on fab'ing the first set mounts (version 1.0) in 1/16" aluminum, this is the "mock-up" mounts to test for fitment ONLY.
Image

The angle of the pipe below is very critical for proper fitment. I used a toilet paper roll (no joke!!) and kept trimming it at an angle until I achieved the correct angle and geometry and then used that toilet paper roll as my template to cut the aluminum pipe.
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After I confirmed that the trial mounts above fit perfectly I then made a new set in much stronger 1/8" aluminum and then my good friend TIG welded it all for me.

Bolted into the car:
Right Side
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Left Side
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All bolted in, nice and strong:
Image

Euro front spoiler mocked-up:
Image

I love this angle:
Image

YouTube Video:
https://www.youtube.com/watch?v=SWHjzpcdyu0

Enjoy!
Yasin

gug
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Re: Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

Post by gug » Mon Sep 14, 2020 3:17 am

Awesome. Thanks for posting this.

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Ralph in Socal
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Re: Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

Post by Ralph in Socal » Mon Sep 14, 2020 5:41 am

Very well done. No butchering necessary that you may be able to manufacture and market those mounts.

Ralph
There is a very fine line between "Hobby" and Mental Illness.

85 635csi Zinno Auto
84 528i Euro
83 635 Euro Arktik
81 528i Kastanien 5-speed
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635sharknose
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Re: Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

Post by 635sharknose » Mon Sep 14, 2020 3:25 pm

Good job, that looks fantastic! =D>
Instagram: @635sharknose
1987 635CSi Bronzitbeige

Slownrusty
Posts: 78
Joined: Wed Apr 24, 2019 2:22 pm
Location: Houston, TX

Re: Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

Post by Slownrusty » Mon Sep 14, 2020 3:47 pm

Thanks guys, glad you thought it was helpful.

While I think it would be cool to put these into production, as I'm a one man show and very busy with my day grind and family, it will probably not happen....but you never know down the road.

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sansouci
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Re: Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

Post by sansouci » Thu Sep 17, 2020 4:10 pm

Could you prepare a set of measured drawings? Put a copyright on it and I'm sure you could sell a few sets. Very well done.
--Ken
Sansouci
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