|If you are building a 6.0 version
of the Diablo, you will undoubtably have had the bumper at least
clamped to the car to determine wing alignment. And for mounting
the bumper, its the first step you need to take. There will
likely be a small amount of fettling required to get it to fit
exactly. In my case the drivers side wing is about 2mm out,
even after taking care with mounting the wings.
Mounting the bumper correctly is also the first stage to accomplish
before bonding the bottom parts of the wings to the front boot
liner. once it is clamped into position, drill through the bumper
and front wing to make your mounting points.
|I am bonding the centre panel which goes between
the two front wings here. The panel has three six millimetre
bolts bonded into it to provide mounting points for the bumper.
At the moment its not fixed in, and requires some more work
as the front boot cover is bonded in.
I have bolted the front bumper to the wings with 8mm bolts,
and have bonded the bolt heads into place to prevent movement.
This will also mean I can fibreglass over the top of them without
fear or obstructing anything I will need to get to later.
|Started lifting this section up with some filler
to match the passenger side. This is the first rough coat of
filler before the lines are refined and the gaps evened up.
I have not fitted the drivers side headlight for two reasons.
One I have run out of the stainless steel I use to make up
brackets. And two, Its a lot easier to sand this section if
the light is not fitted.
Here I have fitted the side lights to the front
Not shown in this photo, is the work I have needed to do to
sort out the ducts at the bottom of the front bumper. The PD
demonstrator I saw has these areas simply blanked off with
the fog lights protruding through them. On the original, a
piece of ducting behind the inlet, guides air through onto
the brake area to maximise cooling. The entire section is covered
with a wire mesh. I had decided to reproduce the original in
this respect, as I have the lower spec brake discs and they
could do with the additional ccoling.
|I have installed the ducts I made in this picture.
I made some patterns up from some shiny thin aluminium, and
used them as plugs which I then layed with fibreglas. The ductwork
is not particuarly aerodynamic but does prevent you seeing
the road through the front of the bumper.
The foglights are not the same type as those on the real Diablo,
but are close enough that it doesnt really matter. I need to
fabricate some small round trims to go around the foglights,
as the trimmed wire mesh, although neat as I could make it,
still looks a bit raggedy.
I finished the bumper in grey primer so that I could see if
there were any glaring errors in my rubbing down. The primer
be rubbed down completely before painting which will help show
any low spots before a final coat of yellow primer is applied.
|This view shows the inside of the bumper. This
would not normally be visible with the front wheels fitted.
You can clearly see the fibreglass boxes I have built, and
the brackets securing them to the bumper themselves.
I used aluminium this time, as there are no welds and I wanted
to keep the weight to a minimum.
|The Bumper here is fitted to the car, and you
can see its a pretty good fit.
The sidelights beneath the headlights are a pain to get fitted
correctly. The small brackets that are moulded into the bumper
leave the light pointing in the wrong direction. I used extra
nuts to space the bracket out correctly. There are slight gaps
visible when the bumper is viewed head-on, so I will probably
run a bead of black sealant around the inside once it is painted.
This is the end result, and very smart it
is as well. You can see the foglights nice and clearly here,
well as the box behind the bumper just like the original.
It took two days to get it looking this good and I have to
at the moment I am pretty pleased with it.
I think my headlights might be a little proud of the front
wings, but as they are both have the same amount of protrusion,
I am not going to change them.
||Got the front bumper back on the car now. I need to adjust the latch for the front boot to stop it bowing down slightly, I will probably put a small shim under the latch ring to just bring it out a couple of millimetres.