Marcel Builds A Bumper

Marc checks the fit between the top and bottom forming dies.

On the Piccolo, the bottom die is in place (right), and the top die is readied.

Once in the machine, the dies demonstrate what the shape will be. Note the tab at the back of the die--this is a stop guide for the edge of the metal that will be fed through the dies.

You can get the curve of a bumper (how it fits around the back half of a body) two ways. The hard way is to cut a straight piece of metal, then stretch it so it gets the right curve; the easy way is to cut the section with the curve already in it, then just form the edge. Following the second method, Marc and Marcel then fed the curved section through the dies.

What you get is a slightly curved center section (which follows the line of the car) with a lip formed over one edge. Two of these pieces are made (one for the top, one for the bottom center section).

Again using the old bumper as a form, the two sections are clamped in place before Marc begins to tack them together. Marcel keeps an eye on the sections so they fit together perfectly.

The top and bottom sections look like this after the entire seam is welded.

Marcel then grinds the welds to create a peak that runs the length of the bumper.

Once the center section and corners are made, they get clamped together over the old bumper.

This is why each piece is made a little long or wide. Using a scribe to etch the metal, Marc shows where the cuts need to be made to fit the two pieces together.

Using simple hand shears, Marc trims the excess metal off each piece.

Tacked together, the end and the center section begin to look like a bumper!

The next section to be created is the outside edge of the bumper (the piece that runs toward the rear wheel). After tracing that template to the sheet, Marc trims it out on the power shear.

Marc uses the same dies as the bumper's center section to start with, but here finishes with the shaper to bend the ends over to the desired arc.

Not quite satisfied with the machinework, Marc goes to the stump to make it right.

Clamped in place, one half of the side section looks like it fits fine. From here the top and bottom side section pieces are welded together.

All five pieces (sides, corners, and center section) are then welded together--and the welds are as clean inside as they are outside!

With the welds ground, the bumper is starting to look like a bumper!

Noting where they were on the original bumper...

...Marc fab's the bumper brackets for the center section as well as for the bumper ends.

And here's the final product. Not an exact clone, but a pretty faithful copy of a bumper you just can't find in your local junkyard! The same build methods employed by Marcel can be used to make a set of custom bumpers for any kit or replica. Any brave souls out there?