Gumball
01-29-2013, 11:35 AM
I've been working lately to fit everything to the body that I think will be easier now before the body goes out for paint and the latest part I tackled was the front bumper. I did the rear bumper the other day and posted my process here: http://thefactoryfiveforum.com/showthread.php?9005-Mounting-rear-bumper-without-dropping-gas-tank
The front bumper was a bit harder to space away from the body because of the rake of the radiator opening and the not-too-symetrical front end. I started by removing material from the sleeves. The passenger side sleeves are both 1/8" shorter than the driver side in order to get the hoop an equal distance from the body on both sides - originally it stuck out about 1/8" farther on the passenger side. I then made the lower sleeves both 1/8" shorter than the top to get a good rake to the overriders and to make it so the mounting tabs on the hoop would align with the back edge of the overriders when it was spaced equally at the top and bottom of the radiator opening. After shortening the sleeves, I was able to use shorter bolts on three of the mounting points, but had to cut down one of the longer bolts for the upper driver side to get the right amount of excess thread sticking out inside the overrider so that I could put an acorn cap nut on them just to finish-off the installation (I'll do the same thing for the allen head button bolts that hold the hoop to the overriders).
I started the initial hoop alignment process by installing the overriders once the sleeves were the correct length, then draping a looped zip tie over each one to catch the tabs on the hoop. That, and a bunch of painter's tape, allowed me to get the hoop just where I wanted it, then I marked for the top hole on each overrider. Once those were drilled, I was careful to re-install everything to make sure I had the bottom holes marked properly. I have to say that drilling stainless steel is not my favorite thing to do, but by being super careful and test fitting everything a bunch of times, I was able to get it just where I wanted it.
Here are a few pictures of the near final test fit. I still need to add the acorn nuts, as well as make sure the gaps in the body around the spacers are uniform and able to hold the rubber grommets that I bought from **********.
http://i845.photobucket.com/albums/ab15/CCRsAC/FrontBumper1_zpsf6ba6e03.jpg
http://i845.photobucket.com/albums/ab15/CCRsAC/FrontBumper2_zpsefade1de.jpg
http://i845.photobucket.com/albums/ab15/CCRsAC/FrontBumper3_zpsaa4ea39e.jpg
The front bumper was a bit harder to space away from the body because of the rake of the radiator opening and the not-too-symetrical front end. I started by removing material from the sleeves. The passenger side sleeves are both 1/8" shorter than the driver side in order to get the hoop an equal distance from the body on both sides - originally it stuck out about 1/8" farther on the passenger side. I then made the lower sleeves both 1/8" shorter than the top to get a good rake to the overriders and to make it so the mounting tabs on the hoop would align with the back edge of the overriders when it was spaced equally at the top and bottom of the radiator opening. After shortening the sleeves, I was able to use shorter bolts on three of the mounting points, but had to cut down one of the longer bolts for the upper driver side to get the right amount of excess thread sticking out inside the overrider so that I could put an acorn cap nut on them just to finish-off the installation (I'll do the same thing for the allen head button bolts that hold the hoop to the overriders).
I started the initial hoop alignment process by installing the overriders once the sleeves were the correct length, then draping a looped zip tie over each one to catch the tabs on the hoop. That, and a bunch of painter's tape, allowed me to get the hoop just where I wanted it, then I marked for the top hole on each overrider. Once those were drilled, I was careful to re-install everything to make sure I had the bottom holes marked properly. I have to say that drilling stainless steel is not my favorite thing to do, but by being super careful and test fitting everything a bunch of times, I was able to get it just where I wanted it.
Here are a few pictures of the near final test fit. I still need to add the acorn nuts, as well as make sure the gaps in the body around the spacers are uniform and able to hold the rubber grommets that I bought from **********.
http://i845.photobucket.com/albums/ab15/CCRsAC/FrontBumper1_zpsf6ba6e03.jpg
http://i845.photobucket.com/albums/ab15/CCRsAC/FrontBumper2_zpsefade1de.jpg
http://i845.photobucket.com/albums/ab15/CCRsAC/FrontBumper3_zpsaa4ea39e.jpg