8 Months Off? The Ebbs & Flows of Building a Unicorn

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…

 

46512″ 12″ x 1/8″ sheet of ABS plastic from Tap Plastics.  Creating a brake/body line for filling the OEM exhaust cutout.

466We heated the plastic up, shaped it, then quickly blew it off with cold compressed air (similar to welding)

467

 

468Piece resting slightly in place.

 

469

470

 

471What was once 4 separate pieces is now 1… Or at least on its way.

472

 

473A push/pull cup set I got for removing bushings (used later on)

 

474An R32 front bumper I got in Oct 2012 finally starting to see some sandpaper

 

475

 

476

 

477small gouge in the bumper from previous owner

 

478Sanded down the front to remove a lot of rash

 

479Our hand-crafted notch-filler tied down and bonded in place.

480

 

481

 

482

 

483-

 

483

 

484

 

485Top piece to fill in OEM exhaust cutout

486

 

487

 

488Picked up new wheels and tires sometime in April
489

 

490reflector recesses shaved

 

491sanding… lot of sanding.

 

492Shaving R32 Front bumper

 

493

 

494

 

495

 

496Reflector recesses sanded and primed

 

497Freshly primed and shaved R32 Front bumper
498

 

499Created molds and troffs

 

500

 

501Step 1: Pour in batter.

 

502Step 2: Let batter rise.

503Repeat Steps 1 & 2 onto opposing side.
504

 

505Step 3: Let cure

 

506Test fitting new wheel and tire package

507

 

508Shaping with ‘cheese graders’ and hacksaw blades

510

 

509

 

511

 

512Beginning to take shape. Literally.

513

 

514

 

515

 

516Fiberglass tape (completely unnecessary.  proved to be more of a pain)

517Acrylic glazing

518

 

519

 

520

 

521

 

522

 

523

 

524High fill primer (for test)
526

 

525

 

527

 

528

 

529First test fitting
530

 

531

 

532

 

533

 

534

 

535

 

536

 

537

 

538

 

539

 

540

 

541

 

542Final priming after many, many sanding sessions.

 

543

 

544

 

545SuperPro Bushing and TyrolSport Subframe Dead Set Kit installation

 

546TyrolSport Dead Set kit install… Prior to stripping frame rail
547

 

548

 

549Custom R32/Votex rear bumper in its final resting place
550Test fitting Votex Sideskirts
551

 

552Pulling dents and dings.

 

553Grind. Sand. Fill. Prime. Repeat.
554

 

556

 

555

 

557Rear badge filling
558

 

559

 

560Final prime of R32 front bumper

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