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Repairing Exhaust cut-out



  BMW E92/Audi S3
Baught a 172 bumper off someone off here a few months back and it has an exhaust cut out of it (Done with scissors by the look of it). Is there any chance i could smooth the exhaust cut out over? How do i go about doing it? I have a mate that is good at body repair, i'm going to do it with his assistance. Thanks.
 
  BMW E92/Audi S3
S6300120.jpg

I want the red circled bit gone :) I dont mind the exhaust cut out as a whole its just he's cut an extra bit for some reason? :S
 
  Punto/Clio GTT
loads of ways you can do it

myself id probably use a filler spreader on the back of it

either screw it down with tiny countersunk screws or stick it down with some sikaflex or other bonding adhesive. then fibreglass for extra strength, then filler/primer/paint
 
  Suzuki Ignis Sport
filler will do it... ask the guy whos selling mirror base plates for some tips coz he randomly filled the holes of his mirror base plates to pratice on.
 
  Punto/Clio GTT
filler will do it... ask the guy whos selling mirror base plates for some tips coz he randomly filled the holes of his mirror base plates to pratice on.

just filler?

no it wont, itll just crack and fall off. just driving down the road will make it crack

you need a foundation to build onto
 
  BMW E92/Audi S3
filler will do it... ask the guy whos selling mirror base plates for some tips coz he randomly filled the holes of his mirror base plates to pratice on.

just filler?

no it wont, itll just crack and fall off. just driving down the road will make it crack

you need a foundation to build onto

I thought the same. Perhaps like a thin piece of plastic card to attach to the inside of the bumper? and then smooth it over with filler?
 
  Punto/Clio GTT
credit card, filler spreader, a cut out from an old bumper, a piece of metal bent to the bumper shape, anything, just scuff it up and the back of the bumper, then bond it down or screw it down.

you can just filler it, but id advise using fibreglass first as it reinforces it and reduces the chances of it cracking in the future
 
  BMW E92/Audi S3
Nice one bud :) I'm gunna get started now, as someone was supposed to buy the bumper off me today but didnt turn up lol
 
  Punto/Clio GTT
yea, easy job.

colour (silver) to just past the bumper recess and just fade it out

then laquer to the white line and fade it out, let it dry n give it a polish by hand

yuyu.jpg
 
  BMW E92/Audi S3
yea, easy job.

colour (silver) to just past the bumper recess and just fade it out

then laquer to the white line and fade it out, let it dry n give it a polish by hand

yuyu.jpg


You helpful motherfucker :approve: thanks lots mate!
 
  Elise S1 B&C 140
I would use fibreglass to bridge the hole from the rear and then skim the front with filler. Other wise tthe filler will just crack as it will have no support. Thats how i did my civic bumper worked a treat.
 
  BMW E92/Audi S3
Yeah, its way too thin to use fibreglass.

So far ive

-Glued a card to the inside of the bumper to use as support for the filler
-Smoothed the "scissor made" Exhaust cut
-First layer of filler

I want to put a 182 surround on it :)
 
  BMW E92/Audi S3
have you scuffed the credit card youve used before fillering?


yeah.. to f**k lol

S6300122.jpg


Just the first layer. Obviously i have to do underneath aswel.

Obviously im going to wait for it to dry and then more layers and smoothage will take place :)
 
  BMW E92/Audi S3
I do have a few pics saved in a folder of what i've done, i will put a guide in the guides section when its done
 
  1.2 Dynamique billabong
i would use some p40 fibre glass mix, put duct tape across the gap on the outside of the bumper, as it doesnt stick to it then apply the p40 from the back of the bumper, once this has formed a solid layer remove the tape then use p38 body filler and sand till smooth.

the same technique was used to smooth in fogs on this bumper

Photo-0155.jpg


Photo-0156.gif


they have sprayed over the p38 filler with high build spray primer
Photo-0193-1.jpg
 
Last edited:
  LY 182
FM - sorry to go a bit off topic but that method you have given for repairs on the silver bumper would that be the same as doing a repair on solid white ?
and also, repairs like that i take it everywhere up to where you have faded the laquer in to would need to be scuffed up with a scotch pad or something - i take it if you scuff to much up you just polish it?
 
  Punto/Clio GTT
yea, scuff further than you need to with a grey scotchbrite or wetflat with something like P1500/P2000 then polish it back to your laquer and itll blend in nicely

yea, same method for all colours
 
  BMW E92/Audi S3
i would use some p40 fibre glass mix, put duct tape across the gap on the outside of the bumper, as it doesnt stick to it then apply the p40 from the back of the bumper, once this has formed a solid layer remove the tape then use p38 body filler and sand till smooth.

the same technique was used to smooth in fogs on this bumper

Photo-0155.jpg


Photo-0156.gif


they have sprayed over the p38 filler with high build spray primer
Photo-0193-1.jpg

Very helpful bud :) im going to smooth one of my fogs off when i get my sport front bumper. Only smoothing the one because the other is going to be used for the cold air feed.
 
i would have done the whole cutout tbh. unless you're poking an exhaust through that bit?

good work so far... slow and steady is the secret.
 
  BMW E92/Audi S3
i would have done the whole cutout tbh. unless you're poking an exhaust through that bit?

good work so far... slow and steady is the secret.

Slow and steady is how im taking it too :)
Its really frustrating, but i've come up with this so far :boring:
S6300128.jpg

S6300127.jpg


I'm having a 2.5" exhaust sticking out nice and subtle and getting it de-catted.
I would prefer the insert to be carbon fibre but i don't think thats available :(
 
  Suzuki Ignis Sport
Looking good, but u're gnna have to cut the exhaust out again, or at least smooth it even, coz it doesn't look even... as in symetrical. (typo?)
 
  BMW E92/Audi S3
**Updated**

Final Layer of filler put on today, some smoothing done and bumper scuffed to bits, then first layer of primer was put on and then prep'd again..

S6300130.jpg


S6300131.jpg


S6300132.jpg


S6300133.jpg


Another coat of primer will go on tomorrow, then more prepping and then paint is going underway next week :)
 


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