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Old 07-11-2011, 12:46 AM   #1
jordanc15
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Default My DIY Front Lip

Hey guys so I got the urge to want to buy a front lip. Checked out the OEM, saw the price, and started trying to work up ideas on how to make one. I got this idea from another member on here who is doing a DIY front grill. Heres where im at so far:

Built the frame of the basic shape out of wooden dowels. Soak them in water to make them bendy then put them on the bumper and tape um in place until they dry. Shape sprung back a little but I was able to work it back to the right shape. Then I moved the frame out about an inch or two. Im still running ideas on how to make this into a fiberglass mold. Im not experienced with fiberglass so this is all a new world to me, any tips or ideas are welcomed. I want to go carbon fiber but I feel to inexperienced to risk messing up the fiber. Plus, I could always do a layer of carbon fiber over the fiberglass once im done and just get the lip clear coated. So many ideas.... Im not sure what to do.

But anyways! Heres the pictures of the current state of the lip.

Got a few angles, the dowels held the body shape pretty well, I think its going to turn out surprisingly well.



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Old 07-11-2011, 04:13 PM   #2
O.C.D.
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Ok, so lets see some more.
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Old 07-12-2011, 02:42 AM   #3
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im working on it! I was busy today so I didnt have time. Tomorrow im free though so I will probably finalize the shape and get ready to make a mold.

Thats the plan at least
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Old 07-12-2011, 03:06 AM   #4
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Nice, excited to see how the project turns out! Would love to see a diffuser too for like the Varis set...
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Old 07-12-2011, 02:52 PM   #5
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Quote:
Originally Posted by mw1484 View Post
Nice, excited to see how the project turns out! Would love to see a diffuser too for like the Varis set...
YES!! Same here. Ill see how this goes first though. I was going to buy the varis diffuser, then I saw the price.... haha. So if this turns out good Im sure ill at least be attempting a diffuser
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Old 07-12-2011, 08:36 PM   #6
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Bravo for taking this on. I'll be watching to see the outcome!
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Old 07-12-2011, 08:47 PM   #7
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ha this thread is like "look i taped some cardboard up front, check it out." full on tease.

good luck with the undertaking, hope the outcome is to your liking.

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Old 07-13-2011, 03:00 AM   #8
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ha this thread is like "look i taped some cardboard up front, check it out." full on tease.

good luck with the undertaking, hope the outcome is to your liking.

This was just day 1. Give me a chance, I did some more work today and Ill throw some pics up tomorrow. And thanks, I hope it turns out good too!
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Old 07-13-2011, 08:22 AM   #9
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It's invisible, OMG!!!!!
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Old 07-13-2011, 01:44 PM   #10
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LoL ... looks like alot of work.... but after all the supplys and time you prob could of bought one for less.... check ebay?
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Old 07-13-2011, 03:45 PM   #11
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DIY > ebay.
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Old 07-13-2011, 05:20 PM   #12
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ill sell you a v-limited style for $100 picked up
its in urethane
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Old 07-13-2011, 05:25 PM   #13
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Don't they sell v limited replicas? My friends bought one off ebay for his 07 wrx for $64 shipped. It's polyurethane and it fits great. Do they not have a replica out yet for the 08?
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Old 07-14-2011, 12:47 AM   #14
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But this way when people ask where I got it I can say i made it, and its one of a kind. If this goes to hell then Ill be searching ebay. But until then im pushing hard on this project
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Old 07-14-2011, 11:14 AM   #15
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Quote:
Originally Posted by jordanc15 View Post
But this way when people ask where I got it I can say i made it, and its one of a kind. If this goes to hell then Ill be searching ebay. But until then im pushing hard on this project
Yup, the glory of making it is a wonderful thing. The anger and sadness you are going to experience the first time you hit a dip to hard and the lip goes scratchy-scratch will out weigh that unfortunately.

But I am a DIYer myself and would still make it regardless. Hell, reinforce it with some mesh?!
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Old 07-14-2011, 03:06 PM   #16
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Quote:
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Yup, the glory of making it is a wonderful thing. The anger and sadness you are going to experience the first time you hit a dip to hard and the lip goes scratchy-scratch will out weigh that unfortunately.

But I am a DIYer myself and would still make it regardless. Hell, reinforce it with some mesh?!
Well Im ganna still have a mold of it. So if I do crack it, and its not repairable then I could just lay down some more fiberglass and make a new one. Im pretty careful about driveways, and im still at stock ride height for now so it wont be as bad
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Old 07-14-2011, 03:09 PM   #17
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Oh and Ive done a bit more work. Im ganna do a little more and hopefully will get some pictures up for you guys.

Thanks for the support
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Old 07-14-2011, 03:11 PM   #18
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Oh and Ive done a bit more work. Im ganna do a little more and hopefully will get some pictures up for you guys.

Thanks for the support
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Old 07-14-2011, 03:19 PM   #19
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Quote:
Originally Posted by jordanc15 View Post
Oh and Ive done a bit more work. Im ganna do a little more and hopefully will get some pictures up for you guys.

Thanks for the support
I'm interested to see how this comes out. If I can make a suggestion though (not telling you how to do your stuff), but you might want to try using foam insulation (you know the pink stuff that goes on the outside of houses?). That's what I used and it was surprisingly easy to work with.

The downside to foam is you can only use EPOXY based fiberglass resin, UNLESS you coat it in EPOXY based primer. If you coat it in that you can fiberglass right over top of the foam no problem.

Good luck, love the DIY, not huge on your use of "ganna" though :P
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Old 07-14-2011, 03:26 PM   #20
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Good luck, love the DIY, not huge on your use of "ganna" though :P
haha funny your mention that. I actually don't like it either. Ive been trying to cut back on it. I actually went with the foam in the first place, my problem is the the part is so big that its hard to keep my lines straight and both sides even. I could easily see using it on a smaller project but for this I felt like it might be more than I could handle.
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Old 07-14-2011, 03:32 PM   #21
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^Actually it was pretty easy. I bought 0.5" foam and did my lip as layers. So you are cutting and shaping smaller pieces. In the end glue it all together with PL300 ($3 at home depot, used to glue foam) and it works well.

Either way... finish and show pics.
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Old 07-14-2011, 03:35 PM   #22
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^Actually it was pretty easy. I bought 0.5" foam and did my lip as layers. So you are cutting and shaping smaller pieces. In the end glue it all together with PL300 ($3 at home depot, used to glue foam) and it works well.

Either way... finish and show pics.
Ya Im already invested into my balsa wood. So Ill continue with the wood and then on my next DIY Ill give the foam another chance.
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Old 07-14-2011, 03:39 PM   #23
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Source free cardboard or styrofoam boards, they make a good base for molds. Using styrofoam takes longer, adds depth, and requires a few more steps. Cardboard will absorb some excess resin from fiberglass cloth and adds to strength without adding weight.
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Old 07-21-2011, 09:51 PM   #24
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Ok guys. So I did this a while ago, but never uploaded pics. Basically all i've done now is covered the bottom in balsa sheets. Im going to cut up some of the left over dowels and put them inside to add more support so it wont flex as much when I go to mold it. Next step will be balsa'ing the top (buying more tomorrow). After that, bondo it to get the right shape and then primer and paint it. Clear coat for a smooth finish so I can wax it, I don't want to run into problems removing it from the mold.

SO! Tomorrow I will balsa the top for sure, and ill do my best to bondo it up. Im 100% free tomorrow and ill be getting up early to dedicate my time to this project.




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Old 07-21-2011, 09:53 PM   #25
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that first picture I posted makes me want to lower the car soooooooooooo badly. Stock ride height is nice, but everytime i see my car i wish is was lower.

Any suggestions for lowering?
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