Re: Wooden Bumpers!

["Hyperaion" <aryasu19@idt.net>]

<x-charset iso-8859-1>Speaking of wood/cars-
I have a photo of some sports-looking type car that some guy made out of
plywood!
The thing actually LOOKS like its made out of plywood. Id like to see the
insurance on that one!


----- Original Message -----
From: Sal Guzzo <yu129742@yorku.ca>
To: <scirocco-l@scirocco.org>
Sent: Monday, December 13, 1999 2:47 AM
Subject: Wooden Bumpers!


> I was walking to a fellow Scirocco owner and he came up with a great idea
> wrt MK1 bumpers. Don't know if this can apply to Mk2 bumpers.  I also have
> pics that he sent me but I'm not including in this post.  Pics sent only
on
> request. Here's his e-mail that he sent me!
>
> Hi Sal,
>
> First let me admit all the abuse I got from my wife during this project.
>
> She kept asking me if she should be making me an appoitment with the
> shrink.  "Wooden bumpers" she would say "You're nuts"!
>
> Anyway...
>
> Modified Bumpers
>
> The original bumpers(front and stern) weigh in around 80 lbs.  The
> Modified bumpers just replace the steel internal structure and the heavy
> pistons with wood and aluminum.  The new bumpers weigh in around 20 lbs.
>
> Materials:
>
> The front and stern 1X6 spruce top piece measures  57 1/4" long
>
> The front and the stern fir ply (good one side) measure 3 3/4" by
>  57 1/4"
>
> You will need 4 pieces of aluminum angle (1/4" stock 1 ‡" X 1 ‡")  each
> 13" long
>
> You will need 12   -1"  #10 Robertson round head screw.
>
> You will need 8   -3/8"diameter  bolts, and nuts in all and 16 washers.
> (You will have to measure the length  -mine are not easy to get at to
> measure...sorry).
>
>
> Procedure:
>
> Remove the front and rear bumpers by unbolting the pistons from the car.
>
> Remove the plastic covers from the steel beams.
>
> Lay the 1X6 spruce piece on top of the steel beam and mark along the
> underside of the board to match the curve of the beam(leave as much wood
> as possible).  Note the  angle between the top of the beam and the front
> is not exactly 90 degrees.  Try to match the angle when you cut the 1X6
> along the pencil line.  Cut the board.  The curve of the 1X6 should now
> match the beam.  (The front beam has more curve than the back beam).  Do
> the same for the stern bumper.
>
> Next lay the piece of ply that you have cut to indicated dimensions
> against the front of the beam so that 3/4" sticks out above the top of
> the beam.  Clamp the ply to the beam.  Carefully mark out the openings
> on the steel beam onto the plywood so that they are the same size.  Mark
> on the ply -front outside and top (so that when it is attached to the
> board, it is correct way around)
> Do the same for the plywood for the stern bumper.
>
> Now use good glue and screw nails to attach the ply to the 1X6 board for
> both bumpers.
>
> For the aluminum supports, allow   5 3/4"  to stick out beyond the
> openings at the front and    5 3/8" at the rear (top).
>
> Hold the bracket in place (flat part up) and stick a pencil through the
> hole in the car  to mark where to drill the aluminum.  Drill 3/8" holes
> as close to the top of the aluminum angle as the 3/8" washer and nut
> (that will be used to attach bracket to car) will allow.
>
> At the other end of the aluminum bracket, drill the holes to attach the
> brackets to the 1X6 board.
> Hole locations are (from the end) 1/4" 1 1/2" and 3" for the front two
> brackets.  For the back 1/4"  2" and   3 1/2" from the end.  I drilled
> 1/4" holes (for the #10  -1" robertson round heads).
>
>
>
>
> Attach the aluminum brackets so that they are sticking out of the car.
>
> Snap the plastic bumper covers onto your wood bumpers and lay them onto
> the aluminum brackets.  Adjust the brackets and decide where the bumpers
> are to sit on the brackets (allowing for the plastic spacers that go
> between the bumper the car).    Screw nail up through the brackets into
> the 1X6 board.
>
> Sort of done.   What I did was remove the bumpers at this point, and
> glued on angled pieces of wood to strengthen the ply at the bottom edge
> to the top.  See the diagram.  Pieces were placed  every 6" front bumper
> and the back bumper.  Then I painted the new wood bumpers black.
> Placed the plastic covers back on the bumpers and screw nailed them back
> onto the aluminum supports with the plastic spacers in place.
>
> Bob's your uncle!
>
> Any questions, ask away.
>
> The pictures are attached.  Let me know if they are attached.
>
>
> Good luck
> Jamie Berry
>
>
>
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>
>


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