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Thread: Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

  1. #1
    Join Date
    Dec 2006
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    CarHeavan
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    75
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    Forced Induction!

    Converting from US Front Bumpers to Euro: How I Did It - Lots of Pics

    My car is a US-Spec '86 CSi Manual.


    I finally completed the fabrication of aluminum mounts to convert the bumpers from the heavy, obtrusive US-Spec ones to the Euro. These mounts I made are 100% bolt-on using all the factory mounting points on the chassis, so no grinding, drilling or welding required on the car. "Let the parts fit the car, do let the car fit the parts" <- is my moto.


    I hope you enjoy the pictures, the YouTube video and they are useful for future owners.


    My car when I first bought it:



    Mocking up the Euro bumper, which I was lucky able to find used here locally in Houston. Its in good shape just needs a bit of TLC, media blasting and paint. I have all the chrome and rubber as well all in decent shape.



    Getting to work on fab'ing the first set mounts (version 1.0) in 1/16" aluminum, this is the "mock-up" mounts to test for fitment ONLY.



    The angle of the pipe below is very critical for proper fitment. I used a toilet paper roll (no joke!!) and kept trimming it at an angle until I achieved the correct angle and geometry and then used that toilet paper roll as my template to cut the aluminum pipe.






    After I confirmed that the trial mounts above fit perfectly I then made a new set in much stronger 1/8" aluminum and then my good friend TIG welded it all for me.


    Bolted into the car:
    Right Side






    Left Side






    All bolted in, nice and strong:



    Euro front spoiler mocked-up:



    I love this angle:



    YouTube Video:
    https://www.youtube.com/watch?v=SWHjzpcdyu0


    Enjoy!
    Yasin

  2. #2
    Join Date
    Nov 2006
    Location
    Brockton, MA
    Posts
    115
    My Cars
    1985 bmw 635csi
    Great Idea! that is one of the best solutions for converting I have seen !

    Pino
    Pino
    1985 635csi
    Brockton, MA

  3. #3
    Join Date
    Dec 2006
    Location
    CarHeavan
    Posts
    75
    My Cars
    Forced Induction!
    Thanks Pino! I appreciate it.

  4. #4
    Join Date
    Mar 2019
    Location
    Burlington, Massachusetts
    Posts
    85
    My Cars
    1985 635csi
    Great job. Love the video

    Sent from my SAMSUNG-SM-G930A using Tapatalk

  5. #5
    Join Date
    Dec 2007
    Location
    PV, CT
    Posts
    301
    My Cars
    525i, MGA, 635csi, e91
    Very interesting. Where was the Euro bumper obtained? I would consider this just due to the aluminum clear coat yellowing on mine.

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