DIY: S14 Kouki light weight (aluminum) bumper support under $10

[gunmetalr32]

i got into a fender bender like 2 years ago and my front bumper support got tweaked. i never got a new one. i just bought a new upper bumper retainer. i got a new bumper (jdm) and got fogs. and painted my car.. over time the bumper started to drag.. i looked for a bumper support and i couldn't find one i really wanted the jdm one since it was light weight.

i looked at my friends bumper support and said i can make something better and way lighter. the usdm looks heavy as fu*k

sorry i forgot to take pictures of the making of the brackets

you can find these aluminum flat bars at home depot, lowes, ace hardware ect

here is the usdm 97-98 bumper support
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-26162903.jpg

here is the bumper support and bumper retainer bolt up
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-26162929.jpg

i did a mesurement on how high the retainer should be (you can eye ball it)

next i made the brackets and drilled holes where it will mount on the retainer
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-26163023.jpg

the way the bracket is bent it is nice and strong ... NO "S" BENDS!!!


this is how it's going to mount on the frame rail
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-26162959.jpg

i decided to make an extra one for the middle
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-26164257.jpg

it needed a little tweaking to fit under the retainer
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-26164317.jpg



ok now lets get started

take off the headlights, corners, grill
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27162618.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27162632.jpg

you can see the retainer sagging
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27163115.jpg

this is where we are mounting the brackets
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27163125.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27163135.jpg

with the brackets not bolted yet
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27164057.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27164113.jpg

now bolted
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27171408.jpg

the middle bolt on the retainer you have to bolt it from the bottom. with a longer bolt and your going to need a locking nut for the bumper


you can already see it's straighter and the sag is gone!
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27171425.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27171443.jpg

now put everything back together

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27172743.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27172758.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27172808.jpg

Before:
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27161300.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27161317.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27161333.jpg

After:
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27174453.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27174511.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-27174524.jpg

Even with heavy fog lights and a greddy lip putting down force

Still holding up strong
http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-30140145.jpg

http://i184.photobucket.com/albums/x198/ADRIANS13/2011-09-30140200.jpg

ALL FOR UNDER $10

[sickstatus]

i need to do this shit...

[gunmetalr32]

i need to do this shit...

i thought you had a bumper support??

it's easy to make and super strong. i should done this a long time ago..

[sickstatus]

I do but it's not flush like yours. One side sags more than the other.

[murda-c]

can you stand on it?

[fliprayzin240sx]

I'd make it stronger...bottoming out your bumper will pull that shit down ever so slowly.

[gunmetalr32]

can you stand on it?

Why would I want to stand on it??? Would that impress you if I could?

I'd make it stronger...bottoming out your bumper will pull that shit down ever so slowly.

it's really strong.. I pushed down on it pretty hard and nothing..

Our streets are pretty bad.. I'll take some pics in a few weeks.. I'll see how it holds up..


Ohh I forgot to mention I bolted the brackets down on the frame rails.

[eddieflo]

This is pretty cool. Keep us updated on how it holds up, because i'm hella curious

[Om1kron]

This is fucking retarded, I for one can tell you from experience that the moment your bumper comes in contact with ANYTHING it will rip that support bar for your hood latch right in half.

Everyone that has an s chassis uses the same damn bar to support an intercooler, eventually the weight from it will cause it to bow back and forth until it snaps in the middle. Hopefully you plan on running hood pins just in case that thing fails.

[sash_ak21]

If you ever actually do hit something, the front of your cars gonna get some serious damage. The bumper support bar is there for a reason.

[jr_ss]

I don't understand and never will why people remove the reinforcement? It's there for your safety... You have and drive a STREET car, not a fucking track car.

[justinbyrant]

there is a reason the stock bumper support is so big and heavy, its because its fucking strong, just stop and think how much damage you would have done in that fender bender 2 years ago if you had done this before then, dont be stupid dude, your plastic bumper and little thin bracket are no match and no replacement for frame rail support

[digiceldrifter]

Can u make a set for me,im really interested pm me thanks