After some sanding and rounding the edges to match the otherside. notice the hole isn’t a circle, but oblong. Not an easy hole to match and place correctly:
And the duct complete:
Still have more fabricating to do on other areas of the bumper, but I was happy that I got the process down well enough to complete in a short time. Started it Friday early evening and the duct was completed as shown on saturday, the next day.
The bumper comes with license plate bracket mounts, which not only look hideous, but i have no inention to use. So i removed them by plastic welding and puddle filling the holes
this picture is from the backside, i embedded some metal screen as reinforcement so the work won’t ever crack in the future:
here you can see the screen/reinforcement at the bottom of the hole:
Completely filled and awaiting to be sanded and smooted out:(will do that tonight)
I also decided it would be a good idea to further reinforce the backside of the splitters. I’m molding the splitters and doing whatever i can do to distribute the forces to improve my chances of avoiding any cracking of my bodywork.
I place a few layers of CF on the backside of the splitter, increasing the bond strenth to the plastic:
I finished up the fabrication portion. In summary, the following changes have been made from original shipment.
-added the air duct to passenger side
-molded the splitters to eliminate a seam
-reinforced the splitters with kevlar and CF
-shaved the license plate mounting holes
