Building a new bumper C7ZR1 on a C6Z
 

Like the title says...building a new face for my baby. I'm really liking how it's progressing. Sourced a 2013 427 bumper as a sacrifice as I didn't feel like cutting up my original bumper as OEM ones are SUPER SCARCE right now.

More progress...

I like the look a lot. :seasix:

It’s been years since I’ve done body work on anything but sheet metal and fiberglass. How do you bond these new plastics together and fill in seams/imperfections?

More pics and the story on the truck.
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We use a product called "Fusor." We're using the 142 for this build as it takes a bit longer to fully "cure" and it will allow us to use heat to mold the two pieces together. But since these bumpers are both urethane, NOT fibergalss, we need to keep them flexible. The Fusor allows that. We also have a special fiberglass mesh (almost like a t-shirt in consistency) that we will use on the inside that will reinforce the overall strength of the bumper, but still allow it that OEM flexibility. More pics to follow this week.

Customers truck. Has been in the shop for a while. Did a cab/bed off full paint job with some metal work on the cab. Left the shop today.

Going to add some titanium skid blocks to the bottom like we did my previous splitter. Shame to go through all this work only to have it destroyed by a stupid curb or parking lot incline.
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Additionally, you can see how the underpinnings are starting to get cut in so everything functions factory or better. We're going to add some steel tabs across the bumper support frame into some j-nuts which will reinforce the entire front splitter in two major locations.

Here's a pic of the titanium I'm throwing on there...
https://www.professionalawesome.com/...n-2-scaled.jpg

This is how we did it on me previous splitter...

I really like how that looks. :seasix:

Now put C7 tail lights on it to really complete the look. :leaving:

Lol...nah. I think the C6 ass looks good enough.

:kick:

Got some good work done this week. A lot of engineering the underpinnings. This is the difference between a great install or a hack job. This is going to be a great install. Got the air dam situated, cut out the area for the side markers, and got the center front aero mounting sorted out. Going to mount some studs through the support pieces to the main splitter reinforcement. Going to hard mount that to radiator bracket. It will be super strong...stronger than the factory setup. Really psyched to get this on the road.

Looking good! :seasix: C6 and C7 owners will do a double take when they see it. I’m looking forward to seeing the finished product.

:withstupid:

Side note, the titanium blocks showed up yesterday.

Side note...that "other place" WISHES they had this content.

I always liked the ZR1 front bumper. Where did you get the ZR1 bumper?
Stock,Bumb ??
What king of power is the C6? Stock, modified?

I got it from Extreme Online (eBay based vendor). It's actually a really high quality piece, better than OEM in my opinion. Stay FAR FAR AWAY from Duraflex. The Z has exactly 575 rw. Full build. That was exactly my target power goal.

More progress...
 

This bumper is still moving along. I admit progress has been slower than I'd like (busy work week, crappy weather, and other projects tying up time), but she is still going. This week we're working on the bumper support foam. We want to keep as much of this as possible because it keeps the shape of the bumper at the top just below the hood line. It's kind of a critical area as air hit that area pretty hard at speed and also fills the large void on the underside of the bumper which can flop around or flex. So, to alleviate that, we're keeping as much of this as possible. Also (not pictured) I ordered a VMS racing tow hook and ZL1addons receptacle. We're going to cut open the main bumper support and weld the receptacle in place. The hook is going to exit right out through the front grille opening where the sensor boxes mount. It's going to be super clean and look like the OEM intended for it to go there. Also, you can see how the underpinnings for the OEM ZO6 air dam are still used and we trimmed what piece (and shape) was needed to bolt the front and center underside all together. Removal is super easy and will only take removing the 4 7mm (OEM size) screws to release from the front. What is seen will stay in place. This thing really is bolting up and coming together nicely.

Looking great! :seasix: