I can address the 8 months “off” but so much has transpired that I’ll just let the pictures (and some blurbs) do the talking for me.
In short, I decided 2 years ago (June 2012) that I would set out to, at the very least, TRY to build an R32 rear diffuser into a Jetta rear bumper. It’s been Trial & Error almost the entire way and we (my dad and myself) did what we thought was right and/or fitting for the application.
Amongst hand-fabricating the rear bumper, an onslaught of other happenings, spendings and parts have popped up along the way. Along with the ill-fated problems and inevitable ‘Murphy’s Law’. Anyhow, lets get into it…
12″ 12″ x 1/8″ sheet of ABS plastic from Tap Plastics. Creating a brake/body line for filling the OEM exhaust cutout.
We heated the plastic up, shaped it, then quickly blew it off with cold compressed air (similar to welding)
Piece resting slightly in place.
What was once 4 separate pieces is now 1… Or at least on its way.
A push/pull cup set I got for removing bushings (used later on)
An R32 front bumper I got in Oct 2012 finally starting to see some sandpaper
small gouge in the bumper from previous owner
Sanded down the front to remove a lot of rash
Our hand-crafted notch-filler tied down and bonded in place.
Top piece to fill in OEM exhaust cutout
Picked up new wheels and tires sometime in April
reflector recesses shaved
sanding… lot of sanding.
Shaving R32 Front bumper
Reflector recesses sanded and primed
Freshly primed and shaved R32 Front bumper
Created molds and troffs
Step 1: Pour in batter.
Step 2: Let batter rise.
Repeat Steps 1 & 2 onto opposing side.
Step 3: Let cure
Test fitting new wheel and tire package
Shaping with ‘cheese graders’ and hacksaw blades
Beginning to take shape. Literally.
Fiberglass tape (completely unnecessary. proved to be more of a pain)
High fill primer (for test)
First test fitting
Final priming after many, many sanding sessions.
SuperPro Bushing and TyrolSport Subframe Dead Set Kit installation
TyrolSport Dead Set kit install… Prior to stripping frame rail
Custom R32/Votex rear bumper in its final resting place
Test fitting Votex Sideskirts
Pulling dents and dings.
Grind. Sand. Fill. Prime. Repeat.
Rear badge filling
Final prime of R32 front bumper