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.
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 for the manufacture of good tuning, in addition to the designer and layout designer, a moulder, a fiberglass technologist and a locksmith are needed. 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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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 mock-ups 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 |
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!
The car service offers car enthusiasts a unique service - the manufacture of external tuning, unusually shaped bumpers, spoilers, and thresholds.
Here are some of our works:
Automotive radiator grilles: tuning them with stainless steel is also within the range of possibilities and interests of our company. Believe me, our artistic preferences and knowledge of the features of the technology of working with stainless steel will give their results, which you will be satisfied with!
You can create your own style and stand out in the crowd, become more noticeable in the evening traffic. You will increase the level of safety on the road, thanks to the fact that you will become much brighter and more noticeable both in the lights of the night city and in the bright sun. All products in our store are covered by a quality guarantee. Due to affordable prices and long service life, which LED strips have, your expenses will be justified very quickly.
Any aerodynamic body kit requires refinement and high-quality installation. Not brought to mind, it has huge gaps and cracks, an uneven surface and other defects. You can bring us your aerodynamic body kit for professional installation or we will make any custom body kit you need.
The cost of installation depends on the quality of the aerodynamic body kit, the type of body kit and is determined after examining a specific set of body kits.
We offer a wide range of lighting elements, such as interior lighting, sets of LED lamps in regular car interior ceiling lamps, designed specifically for a particular car. Car lighting includes universal sets of two-level and two-color illumination of the floor space for two/four points, illumination of interior door handles, changing the illumination and design of instrument scales, instrument tuning, LED illumination of blocks and buttons, installation of additional ceiling lamps and much more!
