Manufacture of metal bumpers to order. Production of an individual aerodynamic body kit

Not infrequently, buyers turn to us with a request to implement an individual aerodynamics project for their car, in other words, to develop and manufacture a body kit, bumper, bumper skirt or other parts for auto-tuning according to a picture or drawing. Turning to us, the client usually presents everything rather superficially and does not suspect what is behind this development, what a titanic amount of work is behind the finished part that a person would like to receive. It would seem that here is a drawing for you, you are specialists, take it and do it. The customer usually suspects that the production of a custom-made bumper will take a little longer than the one already in stock, and the most important and erroneous opinion is that the "custom-made" part will cost the same money as a similar one from our catalog. It's a delusion. The author of the material site ©

In order to comprehend the upcoming scope of work on an individual project, you need to have an idea of ​​​​how the production of tuning parts takes place in general, which are already presented in the catalog on the site, at least in our example, while we draw your attention to the fact that the production process looks the same for everyone without exception auto tuning parts manufacturers. You place an order, let’s say for a bumper, after accepting the order, the seller-manufacturer takes from the warehouse a ready-made matrix, in the production language “equipment” or in the philistine “form” for manufacturing the bumper you ordered, and in it prepares the product for you according to your order. The key here is that the manufacturer takes a ready-made form, so the production time for your order, as a rule, is on average within 2-3 days according to technical conditions and requirements due to manufacturing technology, and the cost of this bumper for you is exactly as much as stated on the seller's website on the day of the order. This cost is calculated by the manufacturer based on the cost of manufacturing the product itself. That is, as you can see, everything is simple, you made an order and, as buyers say, the supplier "cast" the bumper, quickly and "at a reasonable price." The author of the material site ©

Now, based on what we have read, let's consider how your individual order will be implemented, that is, let's assume the manufacture of a bumper for your car, which you did not find in our catalog. The design and shape of the future bumper are agreed with you, then we get to work. There are several ways to implement the project, consider the average. First of all, for the period of modeling work, we need a car similar to the one on which the bumper is modeled, if not for the entire time of work, then at least with a periodic visit to us for fitting. We solve this issue on our own and as a rule it is difficult to find a car for the modeling period, one of the options is to rent a car. Next, we purchase a used regular bumper from the "dismantling", on the basis of which the work will be performed. Having rented a car and purchased a regular bumper, a "modeller" takes over the work, who, using special materials and methods, begins to form, "output" the appearance of the future bumper corresponding to the picture or picture you provided. Only this operation can take at least a week or two, depending on the complexity of the geometry. When the bumper model is ready, the "matrix" is taken to work, he begins to make a transitional, in other words, an intermediate matrix (form) from the received master model. Resin, glass mat and glass mat are applied in several layers with keeping the drying periods of each layer. The term for this operation takes another week. When the transition matrix is ​​ready, the first test product, i.e. the bumper variant, is molded in it. This primary bumper undergoes a thorough fitting and fitting on the car, geometry violations that may have been made during modeling are brought and corrected, all dimensions and distances are checked, as well as the mirroring of the right and left sides of the bumper. This operation may take up to a week. Then the finalized version of the bumper undergoes surface refinement, which is finished with polyester putty, the surface, as they say, is brought to zero, all flaws are eliminated. The term of this operation is 3-7 days. From the finished and final model, they begin to remove the matrix, that is, to prepare the final (finish) form. Resin and matrix glass mat are applied to the bumper while maintaining all the terms and periods of drying of each of the layers. Layers on average can be from 5 to 15, depending on how long the matrix (mold) is planned for. The duration of this operation is 1-1.5 weeks. And only then, when the matrix is ​​ready, a finished bumper is produced according to your project, it will take about 2-3 days to make it. The author of the material site

As you can see, the process of implementing your project, for just one bumper, takes a lot of time, requires serious material investments, this includes renting a car and purchasing a regular bumper, a huge consumption of materials for modeling, as well as paying for the work of a modeler, matrix worker, moulder. As a result, the period is about two months, and the material costs are approximately equal to the cost of five finished bumpers made from this matrix. Therefore, only being clearly aware of the entire scope of work, you need to make a decision on the implementation of the idea and ordering one or another part individually. Usually it is less expensive and many times faster to find something ready-made among the many offers from various suppliers, thereby not overpaying and saving your time. The author of the material site ©

Undoubtedly, the concept of modeling your project presented is partly superficial, the main points of the manufacturing process are touched upon without deepening into the technology, but the general principles are clear and understandable. In conclusion, we can consider several similar projects that we have already implemented earlier.

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What do you think: what element of the car structure is most exposed to various hazards? Most likely you answered correctly - this is a bumper. Wrongly calculated the height of the curb? In the parking lot, did your car serve as an “obstacle” for a novice driver? "Caught" a deep hole hidden by water? Then you definitely need to order a new bumper. Making bumpers to order is our topic for today.

The bumper of a car is the most frequently repaired and replaced part. Original elements are not cheap, Chinese counterparts are a frank “money throw”, besides, they do not always match in size. Therefore, the car owner has only one way out - to order the manufacture of bumpers in the workshop. Of course, you can ride with small scratches and small chips, but sooner or later the bumper will still have to be changed.

Brief business analysis:
Business setup costs: 1 000 000-1 500 000
Relevant for cities with a population: from 400 000
Situation in the industry:the market is not saturated
The complexity of organizing a business: 3/5
Payback: 1.5-2 years

However, bumper replacement is not always the cause of a damaged appearance. Often bumpers are ordered in tuning studios in order to update the look of the car. Creative body kits that can turn an old car into a luxurious car are ordered very often, so the owners of such a business are provided with work for many years to come.

Starting a custom bumper business is no more difficult than, say, opening a mobile tire shop, or organizing a car interior upholstery. The scheme of work can be represented as follows:

Step 1: project development

Most custom bumpers are made strictly to individual design. First, the client voices his wishes for a new bumper, then the designer recreates his vision of the bumper, first on a piece of paper, then in special computer programs for working with 3D graphics. After that, the sketch is shown to the customer, and if approved, it is sent to work. If not, then the sketch of the future bumper is being finalized.

All templates are saved. They will come in handy as a filling for the portfolio of the workshop, other clients may also wish for the same constructive elements.

Step 2: designing the matrix for the bumper

We think you do not need to explain what the word "matrix" means. Its surface must exactly repeat the shape of the future product. The matrix itself can be made of a solid material - metal, technical plasticine, or a special composite. If the client wished to install a bumper with complex contours on his car, then the matrix for the manufacture of such a design is best made in pieces.

Step 3: making the bumper

In order to understand exactly how bumpers are made, whether front or rear, you first need to know what materials they can be made from. There are several options:

• Steel. So-called "power bumpers" are made from it. Usually these can be found on almost any SUV. Moreover, a power bumper is not at all what is called a "kenguryatnik" - they are often confused. The manufacture of power bumpers and their installation is permitted by law, if an appropriate entry is made to the traffic police about changing the design of the car.
• Fiberglass. You can make a fiberglass bumper with your own hands in your own garage, but it is better to entrust this matter to specialists.
• Plastic. Plastic bumpers are the most common option that can be found on Russian roads.

Let's look at making a bumper using fiberglass as the easiest way. Fiberglass is cut into certain pieces and placed inside the matrix in several layers. After that, various resins are added as a binder, which give the structure strength. After some time, the bumper can be removed from the matrix and sent to the next stage - painting.

Tip: in order for the workpiece to easily exit the matrix, Teflon polish is used.

Step 4: painting

Bumper painting is the final step. It is quite difficult to match the paint color to the car, so car owners often order bumpers of a completely different color. By the way, these cars look quite extravagant.

Who to hire

As the practice of other entrepreneurs shows, the bumper manufacturing business can be done by two people. No special knowledge, except for the skills of working with computer programs, is required for this, all the necessary information can be found on the Internet on your own, or you can get advice on our website.

The workshop can easily be accommodated in an ordinary garage, which every second car owner has, so there should be no problems with the area for production. By the way, you can find out what other business you can do with your own garage.

And finally, I would like to give to everyone who wants to try their hand at private business: do not stop achieving your goals at the first failure. It often happens that aspiring entrepreneurs give up, being just one step away from success. We hope this doesn't happen to you. Good luck!

A body kit for a car is a technology for the production of body kits to order.

Just as animals look like their owners, cars reflect the inner world of their owners. One of the ways to emphasize your individuality and highlight your car in the traffic flow is car tuning, that is, changing the technical characteristics or appearance of the car. A body kit for a car is an element of external tuning. A body kit made to order will make your car unique among millions of others in Moscow.

Body kits for a car can not only give it a brutal and strict, or a dynamic and sporty look, but also improve technical characteristics. Tuning body kit reduces aerodynamic air resistance, facilitates handling at high speeds, improves maneuverability.
The body kit of the front bumper serves to streamline the front of the car and better grip on the roadway. Body kits thresholds and rear bumper eliminate air turbulence that impairs the stability of the car. The rear wing also prevents the car from taking off from the road. And the spoiler redistributes the oncoming air flow. Air ducts and air intakes direct airflow to cool the brake system and radiator. Cilia on the headlights, radiator grille, wheel arch extensions, various linings and moldings do not improve aerodynamic performance, but are tuning the car's exterior.

The production of body kits for cars is carried out from different materials, which have their own advantages and disadvantages. So, ABS plastic is distinguished by low cost and lightness, however, it has a narrow operating temperature range and is subject to the negative effects of ultraviolet radiation and chemicals. Polyurethane and carbon have a number of advantages over plastic, however, they are unreasonably expensive. A bespoke body kit for a car made of fiberglass is the best choice in terms of price and quality of this material. A wide temperature regime of application, plasticity, lightness and strength allow you to create from fiberglass - fiberglass impregnated with resin, auto-tuning masterpieces.
The production of custom body kits is a labor-intensive procedure, consisting of several stages.

First of all, you need to decide on the design of the future body kit. It can be either universal, suitable for a similar car model, or made individually according to your drawings and sketches. Then, a body kit tuning model for the car is molded from foam, sculptural plasticine or polyurethane. At this stage, it is possible to make changes and express wishes by the customer regarding the appearance of the body kit.

In the future, 3D technologies come into play. With the help of a 3D scanner, the coordinates of all points of the car are recorded, which is necessary for the most accurate fitting of parts. Also, by means of 3D scanning, the fasteners of the future body kit for the car are determined. Life-size models of parts are modeled using special engineering programs. Subsequently, the 3D model of the car and the computer model of the body kit are compared, and then the matrix is ​​designed.
The manufacture of the matrix itself is a complex and time-consuming process. The operator on the computer builds a model that must be reproduced with absolute accuracy. On modern machines with numerical control, 3D milling occurs with several cutters in different planes according to the coordinates specified by the operator. 3D milling on a CNC machine allows you to accurately and in sufficient quantities produce parts with complex geometry.

Then, according to this fiberglass matrix, body kit tuning parts for a car are made. Subsequently, a wax-based release agent is applied, polishing the surface and facilitating the removal of the part from the matrix in the future. From the inside, the matrix is ​​covered with a special protective and decorative gelcoat composition, which smoothes the relief and prevents the surface of the part from “bubbling”.

The process of manufacturing a part from fiberglass consists of alternately applying fiberglass reinforcing material and special resins to the matrix. Layers should be laid and compacted at the intervals necessary for the resin to cure.
After the part takes on its original shape, it is carefully removed from the die. The final stage is coming. The part is carefully puttied, finally sanded and painted.
This is just one of the ways to make a body kit for a car. The method of spraying, contact molding, pressing, infusion can also be used in the manufacture of custom body kit tuning.

High-quality car tuning gives it a certain character and style. A unique custom-made aerodynamic body kit for the car will set you apart from millions of drivers of identical stock cars in such a huge metropolis as Moscow and will attract the admiring glances of passers-by and neighbors downstream.
All the characteristics of this type of car tuning appear only at high speeds. Installing such a part as an aerodynamic body kit for a car by a non-specialist can lead to a disastrous result. For example, a poorly screwed spoiler that flew off at the time of the race on the highway can cause not only regret about "thrown away" money. Therefore, our specialists will not only produce for you an original custom-made or universal body kit, but also install it.

Body kit for a car to order, prices from:

Acoustic podium in the door	15.000
Bumper	50.000
Hood	50.000
Subwoofer box and stealth	10.000
Whole body	600.000
Cover for headlights (cilia)	4.000
bumper pads	30.000
Hood lining	10.000
thresholds	25.000
Wheel arch extensions	35.000
Radiator grille	20.000
Spoiler	20.000
Tweeter (tweeter)	4.000
false roof	400.000

Any body kit, even small-scale, distinguishes the car from a number of conveyor brothers. And what can we say about the production of body kits to order. A car with an exclusive body kit can go down in history and surprise more than one generation of tuning fans. Let's figure out who and how makes a body kit to order.

Prices for body kits of finished parts can be found in the auto market, in the additional equipment department of an auto dealer, on a specialized website on the Internet, or from a familiar tuning pirate. They will also calculate the cost of fitting, painting and installation. The advantage of a finished body kit is its relatively low cost and predictable result. The disadvantage of an inexpensive body kit is the low quality of workmanship and fit (the manufacturer saves on the quality and quantity of materials, and the installer on the fit time). And only owners of expensive cars (Porshe, Bently, Ferrary, etc.) can count on an attentive attitude - accurate manufacturing and careful fitting of parts. But the cost of these services approaches the cost of manufacturing on an individual project.

From a master by ability.

It is not often that an artist becomes a designer, and even less often a designer becomes a layout designer. And to make a good tuning, in addition to a designer and a layout designer, you need a moulder, a fiberglass technologist and a locksmith. It is clear that in this situation there are not enough good universal specialists for everyone.

Any exclusive body kit begins with a discussion of artistic and technical specifications. If your designer is a good artist, then in a week or two he will prepare a design proposal of two or three options in beautiful drawings. The more beautiful the designer is paid, the more beautiful he draws - after all, the customer implies that the execution will be as beautiful as the drawing ...

Next, the layout designer gets to work. The best option is when the designer himself sculpts the body kit from plasticine, otherwise two will be stomping around the layout - the designer and the layout designer, and two have to pay a salary. In the course of modeling, the modeler (or designer) must apply his knowledge of fiberglass technology, or invite a technologist for consultation. It's good if the technologist and the molder are the same person, otherwise the team grows to a quartet.

A metalworker helps to put the molded parts of the body kit into place, although the manufacture of metal fasteners and amplifiers should not be a problem for a good modeler. Adjusts the gaps and levels the surface of the parts of the body kit, as a rule, the modeler himself, if the preparer from the paint shop does not undertake this work. Isn't it all a bit confusing? What if there is no link? Therefore, universal specialists are highly valued who are capable of doing everything “from scratch”, that is, from drawing to development (testing in one color) of the installed body kit, to do everything on their own. And not only independently, but also quickly and at the same time without loss of quality.

I define the speed test as the time it takes to front bumper manufacturing. For a good craftsman, work can take from three weeks to a month. The rear bumper is usually more concise in shape (but larger) - a few days faster. Two door sills are obtained in three weeks. With arch extensions, depending on their design (for example, a complex closed section), you can carry up to a month.

So that I can live like this ... and work.

Have you ever wondered why it is so difficult to find the executor of your grandiose plans to conquer the tuning Podium? I suspect it's a job specific issue. A good craftsman must master the skills of a sculptor and understand the laws of shaping complex technical objects. Both require a long learning curve, not to mention artistic ability and taste. Multiply these aesthetic tasks by anti-hygienic conditions for their implementation. Can you imagine this Dr. Jekyll and Mr. Hyde rolled into one? Now think about how much money you yourself would agree to do this. Salaries are small and therefore in Moscow, for example, there are only a few such “monsters” of tuning.

Each customer according to his needs.

But suppose we are not interested in these people in masks and protective overalls. The manager who meets you at the "reception" also participates in the distribution of income from the sale of your tuning. But what about the profit of the enterprise, and the cost of rent and materials? What about taxes? Okay, I won't talk about sad things.

The price of the work (especially if you are bargaining with the direct contractor of the project) can be significantly affected by the complexity of the shape of the product itself. For example, the larger the bumper and the more kinks and small parts on it, the longer and more difficult it is to make. An experienced designer can help reduce the price of work if he offers a spectacular and at the same time relatively simple body kit. The luxury of boundless imagination can only be afforded if you have significant funds and time. Deep tuning "in a circle", with the replacement of bumpers, hood, trunk lid, fenders and door linings, can take a team of modelers to work for more than a year.

Count yourself.

Every employee knows roughly how much they pay monthly to specialists in their region. A tuning master, depending on qualifications, earns the same as workers in other fields of activity. The average production time of a part shows how much an employee in a tuning company is paid for it (relative to his average monthly salary for the transaction).

Estimated production time for tuning parts on an individual project(without painting):

————————————————simple complex

1. Bumper front, rear 3 4 weeks

2. Bumper skirt (spoiler) 2 3 weeks

4. Door sills 2 3 weeks

5. Arch extensions 2 4 weeks

6. Rear wing 2 4 weeks

7. Hood 3 4 weeks

8. Wing 2 3 weeks

9. Eyelashes 2 pcs. 2 days 1 week

10. Headlight replacement (new housings) 1 2 weeks

If the employee's salary is multiplied by three, then the cost of the part for the customer in the tuning workshop will be obtained. For a private tuning master, the price of a part for a customer can be a third less than in a specialized company.

Articles about tuning with your own hands.

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* when using spare parts and consumables of the customer and performing single works with a volume of less than one standard hour, the “minimum order for work” rule applies.

Prices for other types of work are calculated according to the standards recommended by the "MITCHELL" catalog.

Prices are indicated in rubles.

Attention!

Cars manufactured before 1997, inclusive, are serviced only after a pre-agreed prepayment.

Diagnostic and locksmith work on cars manufactured before 1997, inclusive, is paid according to the actual time spent.

Warranty obligations "Vita-Motors"

"Vita-Motors" values ​​its customers and therefore bears 100% responsibility for all work performed and spare parts purchased and installed in our service. When contacting us in a warranty case, you must be sure to present a copy of the work order. If in the near future it is not possible to come to eliminate the defect, and by the time of the visit the warranty period may expire - you just need to immediately inform us about the problem upon detection of a malfunction in order to fix the moment of contact, and of course, depending on the malfunction, try not to operate the car so as not to exacerbate the consequences. For example, an oil leak was discovered under the car after an overnight stay, and the client flies away on a business trip or vacation, and so on.

Attention! "Vita-Motors" does not pay for work performed in other services, even if the warranty case has occurred far away - it is better for us to pay for the evacuation of a faulty car, but be sure that this is our fault. I ask you to treat this issue with understanding, unfortunately cases of fraud by dishonest clients have become more frequent.

You changed this and that for me, everything broke down for me, it was far away from you and I fixed it there, I ask you to return the money and / or pay for the repair.

Unfortunately, as the notorious Muller said: You can’t trust anyone .... I can (c)

This, of course, does not apply to our old customers or provided that the service that corrected the defect has long been well known to us. The main thing to remember is that all problems are solvable. Good luck on the roads!

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Services

from 8000 rubles

Astera Vita-Motors will design, manufacture and install any attachments for your SUV:

1. Power bumpers (including under the winch)
2. Power thresholds of any design and fastening
3. Spare wheel brackets (also with movable structure, lockable)
4. Expeditionary trunks for any load, incl. with fastening on a power frame of the car.
5. Power arcs, brackets for headlights, LED beams, etc.
6. "Kenguryatniki", or, as many people like to call them, "donkey cutters" (we don't have kangaroos, but there are a lot of donkeys).
7. Protection of bumpers and thresholds.

And much, much more, both according to your sketches and according to the finished catalog of works, depending on the wishes and scope. It is possible to manufacture replicas of power bumpers and other accessories

well-known brands such as ARB or Jaos.

Production time on average takes about ten days. Painting of finished parts - to choose from:

1. Powder paint
2. Resistant coating U-pol Raptor
3. Durable premium Line-X coating.
4. Automotive enamel. Any colors, at your discretion.

The cost of manufacturing a power body kit:

1. Power thresholds (without installation)- from 18000r.
2. Power bumper (without installation and winch platform)- from 30000 rub.
3. Power bumper (without installation with a winch platform)- from 40000 rub.
4. Expeditionary trunk (without installation)- from 12000r.
5. Spare wheel bracket (fixed, no installation)- from 8000 rub.
6. Spare wheel carrier (swivel/tilt, no installation)- from 14000 rub.

In the presented photos, the process of manufacturing a power bumper from a 4 mm steel sheet with a hidden platform for a Warn winch, with a Cree LED beam, fog lights and power tubular thresholds on the Jeep Wrangler JK, as well as power thresholds with platforms on the Dodge Ram.

All equipment made by Vita-Motors masters, including painting, is provided with a full-fledged guarantee, for the installation of equipment for life!

The power body kits manufactured by Vita-Motors are installed taking into account the design of a particular car, so when using the equipment you will not worry about the power carcass of the car - the load on the elements is calculated individually.

Production of power body kit for Jeep Wrangler JK

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