Production of plastic body kits for cars to order. Production of bumpers for cars

Production of bumpers - replacement of damaged or tuning a new one

Most motorists sooner or later think about buying a ready-made bumper in Moscow or purchasing a custom-made one.

The bumper, being an element of the external decor of a car, can be an element of body kit tuning. And by replacing the stock bumper with the original one, you will give the car your style. And for racing fans, there are options for aerodynamic bumpers that improve the car's streamlining, handling and maneuverability.

The increase in the number of cars inevitably led to an increase in the number of accidents. The most frequently damaged body part is the bumper, which is designed to absorb the kinetic energy of an impact in an accident. The imperfections of the roadway and debris also negatively affect the condition of the bumpers - chips, scratches, cracks appear.

Bumper material: plastic or fiberglass?

The main materials from which bumpers are made both in Russia and for foreign cars are plastic and fiberglass. Details from them are distinguished by their low cost, ductility and maintainability, lightness and strength, lack of corrosion, resistance to chemical and ultraviolet effects. The difference is only in the production technology of bumpers from these materials.

So, fiberglass is several layers of fiberglass, alternately impregnated with special resins. And the composition of the plastic is polypropylene, rubber and a number of stabilizers and dyes.

The process of creating a bumper goes through several stages

The bumper design can either be developed individually according to the drawings or photographs provided by the customer, or be universal, standard for all cars of this model.

The very model of the future bumper is molded from sculptural plasticine. Your wishes will be taken into account, and possible changes in the design will be introduced at this stage. Then computer graphics come into play. The bumper model is entered into the computer with the help of engineering programs. 3D scanning fixes the coordinates of certain points on the car body. A computer model of the bumper is superimposed on the data obtained from a 3D scanner using special graphic programs. Based on the received data, a matrix or technological equipment is formed - a mirror image of the future part.

Bumper production technology

The production of technological equipment or a bumper matrix is ​​a laborious and responsible process. After all, the quality of the part directly depends on the form according to which the part is made. The computer model of technological equipment is absolutely accurately reproduced on milling equipment with numerical control. On 3D machines, it is possible to manufacture matrices with complex geometric shapes. According to a given program, 3D milling is carried out along certain coordinates in several planes. This method of manufacturing a matrix from metal or composite materials is suitable for manufacturing a large number of bumpers.

The production of a custom-made bumper is more jewelry and thoughtful work. First, a rough or intermediate tooling is created. Several layers of fiberglass impregnated with a special resin are applied to the bumper model. After hardening, grinding and coating the resulting form with a protective and decorative gelcoat composition, which prevents the formation of "shells" and microcracks, a bumper prototype is created in it. After manufacturing, the prototype is carefully tried on the car. The dimensions, symmetry and general geometry of the part are checked, and possible minor flaws are eliminated.

The final bumper is then treated with putty and sanded to serve as a model for the finishing matrix, which is treated with a wax polish to facilitate removal of the part and a gel coat. This model is also covered with layers of reinforcing fiberglass impregnated with special resins. Layers can be from 3 to 8-12, depending on the required thickness of the part. To obtain the necessary plasticity and hardness of the material during the molding process, it is necessary to withstand a certain time of thickening and hardening of the fiberglass layers. The resulting bumper is removed from the tooling. For geometrically complex options, several matrices are made, the details of which are then reduced to a single bumper.

The production of plastic bumpers is carried out by injection molding machines. Special granules containing polypropylene, rubber, ultraviolet and heat stabilizers undergo heat treatment and are thoroughly dried. Then they are heated by injection molding machines to a temperature of over 200 degrees Celsius. The resulting composition is poured under pressure into technological equipment, where it takes finished forms.

The resulting bumpers are puttied, polished, primed and painted with enamels for plastic surfaces.

These are just a couple of ways to make a bumper for a car. A custom-made bumper can be produced, including by vacuum infusion or contact molding, as well as by pressing or spraying.

Qualitatively produced and original bumper will give your car a unique image. Our craftsmen will not only make an original custom-made or universal bumper for you, but they will also be able to install it.

Body kit - parts of the car body that perform three main functions:

1. Protection of components, assemblies and metal parts of the body from light damage.

3. Improving the aerodynamic properties of the car.

The body kit comes from:

• polyurethane,
• ABS plastic,
• Metal,
• Composite.

Let's take a closer look at composite families.

Composite body kits are divided into several varieties:

FIRST VIEW:

Fiberglass composite body kits:

Fiberglass is the most common material in the production of body kits and the most popular. Relatively low cost, relatively high technical characteristics firmly fixed this type of body kit in the leader's position.

A huge number of tuning companies around the world have produced, are producing and will continue to produce their parts from fiberglass.

Luma, Hamann, Lorinser, Tech Art, Gemballa, Mugen, Fabulos, APR, Buddy Club, HKS, Blitz, bomex and other global tuning brands successfully use composite fiberglass in the production of their products.

Advantages of fiberglass tuning body kits for cars:

Low cost compared to polyurethane counterparts.

• Excellent maintainability.
• Deep shapes and complex design, inaccessible to ABS or polyurethane body kits.
• Resistant to temperature extremes.
• Manufacturing mobility.
• That is why tuning body kits are made of fiberglass composites.

Disadvantages of fiberglass body kits:

Insufficient comparative elasticity.

• As a rule, a mandatory fit on the car before painting.
• Special requirements for painting fiberglass body kits.
• Human factor. There is a low quality due to the manual production method.

As a result, fiberglass composite body kits divide the market of body kit buyers into two categories -

The first - ardent opponents of composites. As a rule, people who are not interested in tuning or who do not want to change the look of their car and are not demanding on the design of their cars. The choice of this category of buyers will most likely fall on the side of body kits in the factory, made of ABS or polyurethane.

Second, the fans fiberglass cladding. Preferring non-standard options for completing a car. Those who want to stand out from the monotonous stream of the same cars in the stream. Those who understand that the difficulties in fitting or painting such body kits are compensated by their final cost and are ready to go this way.

Both are right in their own way - let's not judge them and move on.

SECOND VIEW:

Carbon composite body kits and tuning parts.

Carbon (carbon fabric).

Kevlar.

Hybrid. (combination of carbon or kevlar with glass materials)

A feature of this group is the technical characteristics of carbon body kits -

Advantages of carbon body kits:

• Lighter weight than fiberglass.
• High tensile strength.
• The thermal capabilities of the material are higher than those of fiberglass.
• Beautiful structure. "Specific production" that does not require painting.

Disadvantages of carbon body kits:

• Time-consuming and costly repairs in case of damage.
• Expensive components - more than five times higher than fiberglass.
• A small range of products offered, due to low consumer demand.

This group of body kits for cars exists rather for selected connoisseurs of tuning. The choice for carbon fiber and Kevlar parts usually falls in case of an urgent need to reduce the weight of the car or add chic in the case of using specific parts. The high cost of materials makes such tuning products expensive and not massive.

However, in motorsport, these products are used with great success. There are currently no substitutes for the carbon body kit group.

(To be continued).

Every person wants to express their individuality. Someone buys clothes, jewelry or collects stamps, and motorists upgrade cars in every possible way. In this case, tuning is the most common way to transform a car. A small number of people can notice the new engine, but the updated body catches the eye right away.

Ordering a bumper or other part in a store is quite expensive, so it makes sense to make a do-it-yourself body kit on a car. With a minimum set of knowledge, you can get a lot of benefits, including:

• Significant cost savings compared to a custom body kit
• The ability to create a unique body kit for the car
• The work is done independently, which means that with due effort it will be done in good faith
• Acquisition of real useful skills

How to make interior tuning we tell in this article. About 3D virtual tuning -.

Preparatory stage

Before you make a body kit, you must dismantle the old one. Depending on the car, body kits can be attached in different ways. For example, the "Japanese" have them glued to double-sided tape and self-tapping screws. Having unscrewed all the bolts, it is required to remove the remnants of adhesive tape. There is an option when the caps are used as fasteners.

With a used car, it can be a little more difficult, because perhaps the previous owner was also a fan of experimenting and secured the body kit with sealant. In order to get rid of its traces, you will have to use professional polishing of the body.

Regardless of the mounting technology, it is recommended to use a garage with a hole or a jack for such work. After detaching the parts, corrosion may be found in the place where the body kit was located. Remove it with a grinder.

Body kit manufacturing

In order to understand how to make body kits for a car, you need to decide what you will make it from. The best material in terms of price / quality ratio is consideredstyrofoam. Before applying it, carefully glue the place of application with adhesive tape.polystyrene foam.

Having finished the preparatory work, we cut it into cubes and stick it where the new body kit will flaunt. The size of the pieces depends on the dimensions of the body kit. Remember to pre-treat the surface that will be adjacent to the machine. Glue the pieces with macroflex . It must be applied in a thin layer. We recommend dicingpolystyrene foamwith a margin. The structure itself is glued in various ways, including:

• High quality double sided tape. Otherwise, the body kit on the car with your own hands will disappear after meeting with puddles
• Sealant, but if you want to remove the body kit again, it can damage the paint

The result obtained is the foundation. The next step is to givepolystyrene foamdesired shape. For this stage, you will need an electric knife, as well as a large skin. When working, it is advisable to pay attention to the following tips:

• Glue cut blocks only on the car
• Your task is to give the piecespolystyrene foamcar body shape. This is done in order to ensure a snug fit of the material to the car body. This solution will reduce the number of cracks and further problems in the following stages.
• It is recommended to lay out the blocks as if brick laying is taking place. Lay them out block by block and meticulously adjust to the desired shape. Of course, you will spend about half an hour on this, but in the future you will understand that the time was not wasted in vain.
• Don't Forget the Minimum Security Precautions

After working with polystyrene foama lot of dirt remains, so there is a possibility that the material can get into the car's air duct. Don't forget to vacuum it.

If you want to make the bumper skirt even, dismantle it and put it on the table. Thus, the work will move faster and better.

Shaping

The shaping of the body is carried out with a large sandpaper of 40 millimeters. Wrapping it on a stick, you get an excellent file. An electric knife is a good tool for rough contouring. Use the "magpie" to give a rough shape. Having reached the limit of half a millimeter to the desired result, go to 80 mm sandpaper.

Regardless of which part of the body kit you make, you need to make every effort to achieve complete symmetry. Before proceeding to the next step, carefully check that all parts of the body kit fit snugly against the body. This work is the most difficult in the question of how to make a body kit with your own hands. Use 40mm sandpaper for adjustments.

Coating

Cover the resulting body kit with a single layer of fiberglass epoxy, which must be cut into small pieces. Apply resin first, followed by fiberglass. Glue the entire body kit. In some places dripping drops of resin are formed. It is recommended to remove them after the resin has cured. At this stage, it will not be superfluous to follow a few tips:

• Stock up on pieces of fiberglass
• To obtain a normal density, lay the fiberglass with an overlap
• Small pieces of fiberglass are easier to glue

A durable layer is achieved by pressing down on the fiberglass with a brush dipped in resin. Run it from the middle to the edges until the material is completely saturated with resin. Avoid the formation of air bubbles.

After drying, start applying a layer of coarse putty. The main problem at this stage will be applying an even layer. This process is necessary to remove all irregularities and flaws. After that, walk sandpaper to remove problem areas. To get the best result, you will have to repeat the procedure several times. Small indentations are removed with putty.

When everything is dry, carefully review the design. Make sure that symmetry is observed and feel free to proceed to the next step on how to make a do-it-yourself body kit. Now you are required to:

• Delete received element from bumper
• Detach the original skirts and wipe them well
• Make a template for the outline of the skirt from the side that is in contact with the fiberglass bumper. Apply multiple layers of fiberglass to keep the template strong
• Carefully unfasten the workpiece from the bumper
• Clear the received part frompolystyrene foam. Do this gradually as the layout loses its rigidity, so treat it with fiberglass and then apply a layer of resin
• Detach the side skirt templates to get the mounting base
• Make a few cuts on the fastening bar, so that later you can connect it to the skirt. Similar undercuts are made on the skirt

Fastening parts

Take a blank made according to a template from the factory bumper mount. Attach it to your skirt with fiberglass and resin. As soon as the structure hardens, fasten the skirt to its regular places using factory bolts.

There is a high probability that the part will sit badly. There may be cracks and discrepancies, but this problem is solvable.

In this case, masking tape and elastic putty will help you, which must be applied along the line of contact between the skirt and the bumper. We are waiting for the solidification of the material. After that, we dismantle the skirt. It will be clearly visible influxes. Remove them carefully.

Now you should increase the flow in the lower part of the skirt, located on the side of the wheel. To do this, take a piece of cardboard. Cut out the desired template and glue it with tape. In order for the cardboard not to lose its shape, strengthen it with two glazing beads . To complete the work on the body kit on the car with your own hands, there are a few steps left:

• Apply multiple coats of fiberglass resin to stiffen the structure
• After the resin, we process the part with putty and level the surface with sandpaper
• You will most likely have to apply several layers of putty to get a smooth surface.
• Try the item on the car

When you have done the whole front of work, you need to pay attention to one detail. When the wheels of the car are turned sideways, a gap in the skirt will be visible, so it is necessary to make protective corners, which are made using elastic putty, cardboard and masking tape by analogy with a stiffener. Now you know how to make body kits for a car.

Undoubtedly, bumper tuning has always been and remains the hallmark of an unusual car. Never will a standard solution provide so many opportunities to express the owner's individuality and create a truly fresh LOOK for the car body. Automotive market trends and technology are moving forward, and with them, and. Today, a wide selection of front bumpers for Porsche, Mercedes, BMW, Toyota, Lexus and many other brands have made the top tuning range the most attractive for the most demanding customers. Unusual and strict, low and high, with daytime running lights and air intake gills - the front bumpers have become the main activator in the direction of external tuning of cars and truly occupy an honorable first place in the ranking of our catalog.

Buying a front tuning bumper or the entire body kit is a matter of approach. Some beginner tuners start by replacing the front bumper and gradually refine the car to perfection by combining elements and creating a unique look. This method distinguishes buyers with a vivid imagination and bold, non-standard solutions in terms of the appearance of a car. The latter, as a rule, prefer brands and are ready to rely on the opinion of professionals who have carefully created the image of a car body kit in a single concept and take into account the specifics of a particular design.

Shop Top Tuning is ready to offer you the maximum selection of front bumpers from the extensive catalog on our website. Choose the car you need and we hope you will find the look you have been looking for!

* 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!

Send price list by e-mail

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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