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BMW E24 US front bumper tuck / lipo

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635sharknose
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BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Thu Oct 24, 2019 5:05 pm

Hope my experience helps you guys a bit. I did read quite some different stories about tucking a E24 US bumper and some of them were pretty strange.

It is quite a simple job that anybody with some technical knowledge can do.
Original front.jpg
Original front.jpg (73.28 KiB) Viewed 2662 times
The original US diving board front bumper
New front.jpg
New front.jpg (91.77 KiB) Viewed 2662 times
Tucked US bumper (1,5 inch / 3,5cm)

Remove the front bumper spoiler, do not forget to unplug the cables connected to the bumper first.

Then remove the bumper itself.
Simplest way is to remove the two M14 bolts (22mm head) of the bumper shocks, they are located near the battery and the other one just on the other side of the front. You also need to take out two smaller M8 screws (head 13mm) on the side of each shock.
Then easily pull out the bumper complete with shocks.

Remove the shocks from the bumper and clean them up.
Mark the distance you want to tuck them in on the shock, I studies photos of the world bumpers and figured out this must be approximately 3,5cm / 1,5 inch.

Now the fun part starts, mark up a drill point in the outer shaft approx. 1cm from the edge and mark a drill point on the inner shaft 3,5cm (1,5 inch) from that hole. Mark them in a straight line, so they match up exactly after you pushed in the shock to the desired size.
Now carefully drill a small hole in the inner shaft until you hear gas escaping, WATCH OUT, it could start spraying oil after it’s punctured (best wrap a towel around the shaft).

Then drill a hole in the outer shell (do not drill through the inner shaft anymore!).

The benefit of just drilling one hole is that the function of the shock remains after it is tucked and locked by a small screw. When you drill a hole in the back of the shock it will lose its function completely. As we now only drilled a hole in the front side, the oil can only escape on this side of the shock.
By putting force on the shock, the remaining oil in the back side of the shock will slowly flow though the inner valve to the front side. The rest of the oil remains and the pressure on the shock remains as well. It will be kept in the exact right place by the screw.
The small screw will most likely break during an impact of a strong hit (parking accident), the shock will then collapse as it was designed for.
Shock 1.jpg
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Now the part comes I read quite some interesting stories about, pushing in the shock.
Pushing the shock with just one small hole drilled cannot be done without force.
I read stories like hitting the car against a wall or tree, placing the shock under a jacked up car and lowering the car after it and some other interesting solutions.
Well, don’t do crazy and dangerous stuff like that, simply put the shock in a vise and wrap a logistic strap around it and gently tighten the strap. Then you will be able to easily tuck the shock and carefully lock it with a screw when it is pushed in.
Shock 2.jpg
Shock 2.jpg (23.46 KiB) Viewed 2662 times
Now place the bumper back on to the car and you will find some new issues to tackle.
One of the issues is the cover plate that is on top of the bumper, a gap of a few mm will be visible from the left to the right side of the bumper, not very nice!
When you take off the cover, you will notice that the first inch of the inner surface is trimmed down a bit to give space for the bumper. But as the bumper is now pushed in much further, it will exceed the trimmed edge and therefore the cover will touch the bumper, pushing it upwards.
I cut the trimmed edge much further out to give it more space. This cannot be grinded, you will have to look for another solution. I did it with an electric wood planer which worked out very well.

Image

Another issue you will be facing is a gap between the side bumper trims and the bumper.
As the bumper is pushed further in, the corners of the bumpers are pushed in a bit too, causing them to drive a bit away from the side bumper trims.

For Europeans (like myself) this can easily be solved. I solved it by exchanging the US license plate holder for a European license plate holder of a European Highline (world bumper) model. These fit to these bumpers perfectly and also fit to the original rubber trims.
After installing the much wider license plate holder, the rubber trims can be moved more to the outside (you have to drill some new holes). Now the thicker (front/corner) part of the rubber trim will be moved to the side of the bumper (the rubber is narrower there originally) causing the gap to close completely.

I will add a new post about the rear bumper in a while as well.
Last edited by 635sharknose on Sat Oct 26, 2019 5:07 pm, edited 3 times in total.
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Re: BMW E24 US front bumper tuck / lipo

Post by 87Shark » Thu Oct 24, 2019 9:09 pm

Good write up, but your pics did not come thru. Any way to re-post them or can an admin. help with this? Would like to see the before and after.
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635sharknose
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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Fri Oct 25, 2019 3:30 pm

Thanks! Uploaded them to another server, I hope they are visible to you now.
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Re: BMW E24 US front bumper tuck / lipo

Post by GRNSHRK » Fri Oct 25, 2019 4:25 pm

Only a few pix still coming up :-k

Why not just load them directly instead of using a photo hosting site :-" :-"

Definitely interested in this as well [-o<
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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Sat Oct 26, 2019 5:08 pm

Hope now the 5 pics are visible. Didn't know it was possible to upload to the forum as well. Managed to upload 4 pics max. the 5th is on a server.
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Re: BMW E24 US front bumper tuck / lipo

Post by hornhospital » Sat Oct 26, 2019 6:27 pm

If you want to upload more than 4 pictures (I thought it was 3) just make a second reply to the thread, and upload the pictures 3 or 4 at a time.
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Re: BMW E24 US front bumper tuck / lipo

Post by sauber » Sat Feb 08, 2020 7:25 pm

Have you finished the rear bumper?

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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Sat Feb 08, 2020 7:30 pm

Not yet, working on a different item on the Shark first. As soon as I have it ready I will post it.
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Re: BMW E24 US front bumper tuck / lipo

Post by Slownrusty » Sun Mar 15, 2020 12:30 pm

On the front bumper, it looks like about 1.5inches were tucked?

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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Sun Mar 15, 2020 12:34 pm

Yes, in fact it was 3.5cm but that is close to 1.5 inch.
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Re: BMW E24 US front bumper tuck / lipo

Post by Slownrusty » Tue Mar 17, 2020 12:22 pm

Thanks for the reply - good reference.
I removed the US Bumpers from my car and in the process of fabricating my own brackets to mount a set of Euro bumpers, I hope to complete them in a few weeks.

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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Tue Mar 17, 2020 12:26 pm

That's great, please share photos when ready.
You are going to update to old style chrome Euro bumper correct? Not the late model world bumpers?
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Re: BMW E24 US front bumper tuck / lipo

Post by GRNSHRK » Tue Mar 17, 2020 4:11 pm

635sharknose, can you please share a photo from the front showing how much space is remaining between the bumper and side cover [-o<

Agreed that it does look great from the side, but I am concerned that there may be too much space showing :(
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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Tue Mar 17, 2020 4:35 pm

On my car the gap is zero, see photo.
The reason for this is that I have added a Euro license plate holder (of a 88/89 model) and moved the existing rubber strip outwards.
When moving them outwards, the thicker piece of the strip goes around the corner and closes the gap.
With a US license plate holder you will have a gap, it will be about 5mm if I remember correctly.

BMW part no. of the 88/89 Euro license plate holder: 51111967620
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Re: BMW E24 US front bumper tuck / lipo

Post by GRNSHRK » Tue Mar 17, 2020 6:28 pm

Ah, interesting, more to the story :-k

But 5mm isn't much of anything, might be that much in original (stock) condition [-o<

Now you're gonna make me go out and take a look :roll:

Edit: just looked, and it's tight :-?

I would have to measure to see if the tuck would create a space there, as it appears that the rubber does start to curve within a couple cm's :-({|=
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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Tue Mar 17, 2020 6:52 pm

Glad it helped!

The original license plate holder is 33.5 cm wide.
The Euro model is 56 cm wide, much wider than the US model.
This results in a difference of 11.25 cm per side (4.4 inch).
I am sure the rubber is thinner at the end, I do not know how much though and am not able to measure it as it is inside my bumper now :D
If you measure the thickness at the point where the side trim starts and then 4.4 inch inwards, you will know.
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Re: BMW E24 US front bumper tuck / lipo

Post by sauber » Wed Mar 18, 2020 9:39 am

Is this part 51111967620 avaliable new?

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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Wed Mar 18, 2020 10:02 am

Yes, it is, and it is not an expensive part.
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Re: BMW E24 US front bumper tuck / lipo

Post by 86_6series » Sat Mar 21, 2020 6:50 am

Looks like the air dam was replaced. World air dam on a US spec bumper.

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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Sat Mar 21, 2020 7:12 am

Yes it was replaced. I am doing a total world bumper conversion, just like you :D
I do have almost all parts for it, just miss the right rear bumper trim and the 2 strips on the front bumper.
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Re: BMW E24 US front bumper tuck / lipo

Post by sauber » Fri Jun 05, 2020 2:56 pm

Hallo.

I also moved the bumper more inside, only I didn’t cut the rubber, but the aluminum bumper.
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Re: BMW E24 US front bumper tuck / lipo

Post by 635sharknose » Fri Jun 05, 2020 3:02 pm

That is also a good idea to cut the bumper instead of cutting out the top cover plate.
End result looks very good, well done!

I see you also used the Euro Highline model license plate holder. :D
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Re: BMW E24 US front bumper tuck / lipo

Post by sauber » Fri Jun 05, 2020 3:13 pm

Yes of course, I had good instructions, thanks :D Now it will be necessary to fix the rear bumper :-k

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