RS4 bumper installation/modification

Nogaro Stg3 · 11-03-2005, 06:34 AM

I searched but was unable to find any specific info on "heat molding" the bumper to fit on my S4.

My shop will be doing the install but they want some sort of instruction so they dont overlook anything.

Is there any modification needed to the fenders? Or just the bumper? Does anyone have instructions or any help?

TIA

JasonS4+Festicle · 11-03-2005, 06:50 AM

3Scanner · 11-03-2005, 06:58 AM

for the backside of the RS4 bumper, right where the bumper edge meets the front fender panel on each side of the car. My shop took this route instead of using heat and they were able to make the bumper match up with the fender flare of the front quarter panels. Once the bumper was mounted and in the correct position, they attached the unit with screws coming down from the fender flare into the upper edge of the RS4 bumper (right where it aligns with the fender, near the side of the car).

You should note that this was the first time this body shop did any type of RS4 bumper modification. They are pretty good with other types of cars, but were straight with me about never having done this type of work before. As a result, it was somewhat of a risk, but everything turned out for the best. You may want to ask members on this board for names of shops near your location that have done this type of work before. Lastly, the labor cost for paint matching and installation of the OEM-RS4 bumper for my car was $830, in case you were wondering.

Sorry I don't have any pictures to show you and if it is difficult for you to visualize. Hope this helps.

TwinTurboTerror · 11-03-2005, 07:02 AM

Note: You probably don't want to use as much filler (if any at all) as described below, as that stuff will crack off if you ever hit anything with the bumper.

Instructions

1. Remove stock bumper

2. Remove stock mounts (US Version)

3. Install RS4 mounts.

4. Cut the top of the RS4 bumper at the fender seam locations, probably about 3/8" is trimmed IIRC to clear US fender seam as it rolls down.

5. Install RS4 bumper on car, using the front bolts only.

6. Drill mounting holes through bumper ends near the back of the headlight locations and into fender seam (1/4" dia. holes)make sure to center in the fender seam to allow clearance for nut.

7. Insert 1/4" bolt, and flange head nut or washer and nut.

8. Heat bumper and work the correct shape so ends of bumper are flush with fender
well. While doing this and once molded to desired shape, use a clamp to hold bumper in place at wheel well, again drill hole in center of fender seam.

9. Insert another bolt and nut.

10. Check final fit if more heat is needed go ahead and mold again, once satisfied, drill one more hole at end of fender seam at the wheel well location.

11. Insert last bolt and nut.

12. Once all heating is finished you will most likely have a concave area in the middle of the fender seam about 1/16", you can leave this if you are not picky or you can choose to fill in area with a filler such as 3M3M AutoMix -
05887 EZ Sand Flexible Parts Repair and
05907 PolyOlefin Adhesion Promoter for TPO repair.

13. Prepare filler material and apply to extend beyond the gap along the fender seam.

14. Let filler harden as per manufacturer specs.

15. Wet sand to final contour

16. Repeat procedure for other side.

17. Remove Bumper, it should be ready to be primed and painted.

18. Re-install is a snap since all holes and alignment was already done.

3Scanner · 11-03-2005, 07:07 AM

Nogaro Stg3 · 11-03-2005, 10:06 AM

3Scanner · 11-03-2005, 10:06 AM

JasonS4+Festicle · 11-03-2005, 10:12 AM

Nogaro Stg3 · 11-04-2005, 06:06 AM

they tell me they used to do alot of custom stuff when they used to be astoria, queens.

so im gona let them give it a try, just looking for good directions to help them out as much as i can so it comes out beautiful.

any special hints/tips?

EdyJun · 11-04-2005, 10:34 AM

11-03-2005, 06:34 AM	#1
Nogaro Stg3 New Member Account #: 87234 Join Date: Jan 2005 Posts: 453	RS4 bumper installation/modification I searched but was unable to find any specific info on "heat molding" the bumper to fit on my S4. My shop will be doing the install but they want some sort of instruction so they dont overlook anything. Is there any modification needed to the fenders? Or just the bumper? Does anyone have instructions or any help? TIA

11-03-2005, 06:50 AM	#2
JasonS4+Festicle Senior Member Account #: 36810 Join Date: May 2002 Posts: 7,229	where do you live? You might want to find a place that's done them before.

11-03-2005, 06:58 AM	#3
3Scanner Member Account #: 43051 Join Date: Sep 2002 Posts: 3,301	Another option is to avoid heat molding and, instead have your shop create custom braces... for the backside of the RS4 bumper, right where the bumper edge meets the front fender panel on each side of the car. My shop took this route instead of using heat and they were able to make the bumper match up with the fender flare of the front quarter panels. Once the bumper was mounted and in the correct position, they attached the unit with screws coming down from the fender flare into the upper edge of the RS4 bumper (right where it aligns with the fender, near the side of the car). You should note that this was the first time this body shop did any type of RS4 bumper modification. They are pretty good with other types of cars, but were straight with me about never having done this type of work before. As a result, it was somewhat of a risk, but everything turned out for the best. You may want to ask members on this board for names of shops near your location that have done this type of work before. Lastly, the labor cost for paint matching and installation of the OEM-RS4 bumper for my car was $830, in case you were wondering. Sorry I don't have any pictures to show you and if it is difficult for you to visualize. Hope this helps. __________________ ================================================== ===================== ================================================== =====================

11-03-2005, 07:02 AM	#4
TwinTurboTerror Member Account #: 3779 Join Date: Apr 2000 Posts: 13,279	Here are the instructions I gave my shop that I found on AW: Note: You probably don't want to use as much filler (if any at all) as described below, as that stuff will crack off if you ever hit anything with the bumper. Instructions 1. Remove stock bumper 2. Remove stock mounts (US Version) 3. Install RS4 mounts. 4. Cut the top of the RS4 bumper at the fender seam locations, probably about 3/8" is trimmed IIRC to clear US fender seam as it rolls down. 5. Install RS4 bumper on car, using the front bolts only. 6. Drill mounting holes through bumper ends near the back of the headlight locations and into fender seam (1/4" dia. holes)make sure to center in the fender seam to allow clearance for nut. 7. Insert 1/4" bolt, and flange head nut or washer and nut. 8. Heat bumper and work the correct shape so ends of bumper are flush with fender well. While doing this and once molded to desired shape, use a clamp to hold bumper in place at wheel well, again drill hole in center of fender seam. 9. Insert another bolt and nut. 10. Check final fit if more heat is needed go ahead and mold again, once satisfied, drill one more hole at end of fender seam at the wheel well location. 11. Insert last bolt and nut. 12. Once all heating is finished you will most likely have a concave area in the middle of the fender seam about 1/16", you can leave this if you are not picky or you can choose to fill in area with a filler such as 3M3M AutoMix - 05887 EZ Sand Flexible Parts Repair and 05907 PolyOlefin Adhesion Promoter for TPO repair. 13. Prepare filler material and apply to extend beyond the gap along the fender seam. 14. Let filler harden as per manufacturer specs. 15. Wet sand to final contour 16. Repeat procedure for other side. 17. Remove Bumper, it should be ready to be primed and painted. 18. Re-install is a snap since all holes and alignment was already done. __________________

11-03-2005, 07:07 AM	#5
3Scanner Member Account #: 43051 Join Date: Sep 2002 Posts: 3,301	Nice!...EdyJun should put your instructions in his directory. __________________ ================================================== ===================== ================================================== =====================

11-03-2005, 10:06 AM	#6
Nogaro Stg3 New Member Account #: 87234 Join Date: Jan 2005 Posts: 453	long island, new york

11-03-2005, 10:06 AM	#7
3Scanner Member Account #: 43051 Join Date: Sep 2002 Posts: 3,301	Rojo Collision is the place to go, I think. __________________ ================================================== ===================== ================================================== =====================

11-03-2005, 10:12 AM	#8
JasonS4+Festicle Senior Member Account #: 36810 Join Date: May 2002 Posts: 7,229	Yep, Rojo. I'm from Chicago but the NY place that comes up here all the time is Rojo.

11-04-2005, 06:06 AM	#9
Nogaro Stg3 New Member Account #: 87234 Join Date: Jan 2005 Posts: 453	im pretty loyal to this body shop...they do great work... they tell me they used to do alot of custom stuff when they used to be astoria, queens. so im gona let them give it a try, just looking for good directions to help them out as much as i can so it comes out beautiful. any special hints/tips?

11-04-2005, 10:34 AM	#10
EdyJun Member Account #: 48484 Join Date: Dec 2002 Posts: 2,849	<Tracking> __________________ 2000 Audi S4 STG 3 FATS = 3.66 w/ 91 oct AIM: EdyJun 11 September 2001 In their honor. In their memory. <font color="red">---------------------------------------------------------- <u><big> <a href="http://homepage.mac.com/edyjun1/S4/index.htm">EdyJun's S4 Directory (FAQ, DIY, Info, Tips and Help) </a> </big> </u>---------------------------------------------------------- </font>

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