Need suggestions: Cutting bumper for dual exhaust

Safety first

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2 coats of primer then light sand

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first base coat. This is where i am now. 1 or 2 more to go, then clear

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Are the inserts/bumper plastic or metal? Should have used an adhesion promoter if those inserts were plastic, but they should be fine...



As far as cutting, if you are good with a jigsaw, it would make easy work of that with a metal cutting blade on it. If I can follor a line perfectly with mine, you could... lol. The inserts should cover up and rough edges though, so I wouldn't worry about making the cut TOO pretty, just make sure it's right.
 
Joseph K said:
Are the inserts/bumper plastic or metal? Should have used an adhesion promoter if those inserts were plastic, but they should be fine...



As far as cutting, if you are good with a jigsaw, it would make easy work of that with a metal cutting blade on it. If I can follor a line perfectly with mine, you could... lol. The inserts should cover up and rough edges though, so I wouldn't worry about making the cut TOO pretty, just make sure it's right.
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I scuffed the surface with 320 grit wiped with prep-sol and primed. Since it's not a really flexible plastic, i should be fine not having been able to find plastic bumper specific paint.



If you read back, you'll see the work we did with tin snips. Ended up being a very nice cut. It's probably what I'd recommend now for cutting this type of plastic bumper cover. The lip on the inserts is big enough that i could have cut it out with a hatchet :D



Joseph K said:
Looks nice, man. I bet it sounds a lot better, too :D
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It's pretty quiet actually, but it does have a bit of a grumble to it now. Just enough to raise an eyebrow if you were very attentive, but not enough to make anyone think twice. I tried to take some video on my camera, but it's not even worth posting because the little microphone on the camera can't pick up the bass, so it sounds tinny and generally crappy in the video.



anyway...3 coats. Will be ready for clearcoat after drying for a couple hours.



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I'm gonna mount them on the bumper Friday. that gives a couple days for the paint to cure and it's the first day it won't be raining. Gonna use the polyurethane adhesive after sanding and prepping both surfaces, then tape it up with my blue trim tape for 24 hours.
 
You're doing a real nice job with that mod. Props to you. Modding is so fun when you do it yourself. THis is especially true with cosmetic mods IMHO.



Looking forward to the results.



JJ
 
victory- Just be a *little* careful pulling the tape off. I know, the blue stuff is supposed to be issue-free, but anyhow...
 
haven't had a problem with the 3m tape. Other brands of blue tape, yes, issues.



Regardless, the car needs a polish, and i've been planning to do it for weeks, just that it didn't make sense since i was doing all this work to the car and you inevitably end up getting your greasy hands somewhere they shouldn't be.
 
Nice job victory..... I think it looks great :xyxthumbs.



The fascias and pipes (tips) really add to the rear of the car. You did your research well and the finished results show it.
 
looks good. a guy up here did that last fall to his GS. HOT HOT HOT.

on a side similar note another guy did 3" exhaust to a huge muffler and a single one of those tips. and well by the time he returned that tip was coming off. at 1/2 throttle or more it sounded like a train whistle. too funny, but it had to go he said. he wanted to keep the single exhaust.



the guy that did the dual setup had issues over the winter with the inserts falling of once it got cold. and let me tell you it gets cold up here.



my only concern is will that exhaust be enough to support the pulley you bought? i know you got the other parts of it covered. would suck is all to go through all that with the GTP exhaust and it not be enough flow.



definitely sexy with those tips and duals on a GS though.



Monty
 
Wondering the same thing here is the stock exhaust off another car the way to go? seems weird to me when you could of just got off brand mufflers and piping made for it at a local shop. Good to see someone with a DIY attitude aswell. I hate seeing people now days who cant do anythings themselves. Cutting and paint work looks great by the way.
 
spike_africa said:
Wondering the same thing here is the stock exhaust off another car the way to go? seems weird to me when you could of just got off brand mufflers and piping made for it at a local shop. Good to see someone with a DIY attitude aswell. I hate seeing people now days who cant do anythings themselves. Cutting and paint work looks great by the way.
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The major restriction with the stock GS catback is the single muffler, not the piping. A stock GTP exhaust will handle 300whp and i won't be anywhere near that even after the pulley swap. Most guys don't touch the catback aside from removing/replacing the resonator until they are pushing a lot more power...unless they just want to make a lot of noise.



All aftermarket exhaust systems sound like @ss on a 3800. Many people have clearance issues with a single 3" exhaust and it sounds like @ss. The only way to get close to what i paid for duals with similar performance would be a larger single aluminized pipe to an aftermarket muffler, which would rust and sound like @ss.



musthavemuzk, my tips are welded, not clamped. My bumper inserts will not fall off in cold weather. Many guys use double sided tape which is why their inserts fall off as the hot/cold wet/dry cycle degrades the tape and adhesive. I used PL polyurethane construction adhesive. If you are not familiar with this product, let me tell you, my bumper will come off before my inserts do.
 
That looks great, I like how it looks factory but still performance oriented. Perfect choice on the tips too, but I just like em cause I have the corsa ones that look the same
 
why would anyone think dbl sided tape would hold on those inserts?

he used 3m epoxy on his and it still failed. i never asked him what he used to put them back on though.

i am pretty familiar with liquid adhesives. used them on sub boxes for years.



Monty
 
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