Jeff Lilly
  • Home
  • Shops
    • Mechanical Shop
    • Media Blasting
    • Body Shop
    • Block Sanding
    • Wood Work
    • Paint Shop
    • Upholstery Shop
    • Assembly Shop
  • Gallery
    • Restomods
    • Hot Rods
    • Muscle Cars
    • Pro Touring
    • Trucks
    • Corvettes
    • Classic Cars
    • Frame Off
    • Pre-War
  • Why Us ?
    • Why Choose Us
    • Build Process
    • Beginnings
  • Cost
  • Contact
  • Recognition
    • Endorse
    • media
  • Build Tips
  • Employment

Build Tips

Smooth Fit Bumper

1
Click to enlarge

We start with holding up the original bumper and checking its natural shape, then deciding if we want to change the outer shape some or leave it stock.

2
Click to enlarge

We have decided the original outer shape is decent so we start by using chip board stock which is stiff enough to hold a shape yet flexible enough to get it shaped in the first place. Mani bends it over the original bumper end and we are on our way.

3
Click to enlarge

Both sections are done. Sometimes you will find a multiple sided bumper. You can opt to make only the side that fits the vehicles body and alter the other shapes or recreate the same shape only tighter fitting to the body as we did here. We will make the complete bumper to show you all the techniques.

4
Click to enlarge

Next we lay out and cut the exact shapes in 18 gauge steel.

5
Click to enlarge

Mani uses a planishing hammer, but for the hobbyist you can simply use a block of wood or shot bag and a body hammer to get the shape going the right way.

6
Click to enlarge

As seen he has a curve in the panel that matches the original shape but he leaves extra metal on the ends in order to allow " fitting" to the body or qter panel.

7
Click to enlarge

We use an English wheel to roll out all the power hammer marks but with a shrinking or slapping file and a dolly you can achieve the same thing at home.

8
Click to enlarge

This piece compared to the other section is much more gradual but it matches its bumper section.

9
Click to enlarge

A little hand tweaking over a round surface as in our case a t-dolly Mani massages it in to shape.

10
Click to enlarge

It is starting to take shape but it needs some more tweaking.

11
Click to enlarge

A little more and she fits much better.

12
Click to enlarge

The inside piece looks pretty good also. A bit more refinement and she will be dead on.

13
Click to enlarge

Mani tacked them in place and went on to mock up the splash pan which needs to compliment the bumper and glide away smoothly to keep with the overall shape.

14
Click to enlarge

As seen there are some relief cuts where the chip board has to be bent.

15
Click to enlarge

This one calls for more angles, you can hand tweak this over your knee, round pipe or use an English wheel for speed as we do .

16
Click to enlarge

It is coming around and has a few relief cuts to help the bend.

17
Click to enlarge

Getting closer.

18
Click to enlarge

A bit more hammer work to tweak it in to shape is needed.

19
Click to enlarge

A little more wheeling, notice the rubber band on the large wheel as this is much more aggressive and speeds things up.

20
Click to enlarge

Coming together it is time to trace the orig metal and cut away the old panel to butt fit and tack weld.

21
Click to enlarge

Looking better a little more tweaking.

22
Click to enlarge

You can see how the inner structure was cut out to make room for the tail panel / bumper section.

23
Click to enlarge

A few tacks while working it and she is coming together.

24
Click to enlarge

Once welded she looks great.

25
Click to enlarge

The bottom curve is looking good also.

26
Click to enlarge

Next we make the bumper brackets. In our case the Mustang bumper is right up against the back of the tail panel so short brackets are all that's needed. We use simple flat plate to weld the nuts to.

27
Click to enlarge

Bolts and nuts for mounting will be welded.

28
Click to enlarge

Tack welded on and ready to build the remaining brackets.

29
Click to enlarge

Several curves, we are ready.

30
Click to enlarge

Mani fabs the bumpers main brackets by bending them in our Tennsmith brake.

31
Click to enlarge

You get a good idea on how the brackets will be secured to the body from this photo.

32
Click to enlarge

After tack welding we will fully weld it in solid once we are happy with our fit.

33
Click to enlarge

The other end piece was fabricated for the driver side. Then Mani bent some 18 gauge in the same shape as his brackets only slightly larger for the bumpers center section. As seen he made it a bit longer also. This will allow him to cut away some metal to help the curve and or transition from the outer pieces come gradually in to the center section bumper.

34
Click to enlarge

We bolted it up to be sure we were headed in the right direction and sure enough, we are.

35
Click to enlarge

Close up shows how the brackets fit the bumpers precisely.

36
Click to enlarge

Mani is pleased, so on to the next phase.

37
Click to enlarge

Close up shows a nice curve rolling gradual in to the center piece.

38
Click to enlarge

To cap off the bumper is the final touch. This piece was made after a template and is now ready for fitting and welding.

39
Click to enlarge

Tacked on she fills the void and also strengthens the end of the bumper some what.

40
Click to enlarge

This angle shows the bumper finished and ready for full welding.

41
Click to enlarge

She is fully welded and ready to be ground smooth or metal finished.

42
Click to enlarge

All together and now we have one wild Stang with a custom fitted bumper to the body all rolled in to one bad wam "Frankenstang" package

Jeff Lilly Restorations

11125 FM 1560 N San Antonio, TX 78023

210-695-5151 - FACILITY TOURS BY APPOINTMENT ONLY

Mon- Fri 8:00 - 5:00

The look, feel and sound, you've seen it finished in your minds eye a thousand times. The years go by, as time slips away with the old enemy "procrastination". If it is time to get it done, contact us today to get your machine rolling down the road in style. Please take the time to read the Cost / Faq section by clicking HERE This section will help inform you about the car building process to help you make your best decisions.

Thank You! To contact us with your questions call 210-695-5151 and to send photos or information about your project email us by clicking here.

Follow Us For More

© 2023 Jeff Lilly Restorations