Front bumper bracket

[FIFTY]

Not good news guys, seems like there is a bit of a design flaw with the main front bumper bracket where water pools under the polystyrene and the L shape part of the bracket which tucks underneath and eventually it rots spectacularly... the rust has spread onto the front accident brace. I have cought it before it went through thankfully it is still on the surface on the brace but the bracket is totalled (mild steel)

I need to get one fabricated out of stainless. Do you think the people who laser cut my exhaust flanges can help? I am worried they might ask for a CAD drawing and I have no clue... if anyone has the skills and some spare time I can take measurements!

I reckon as these cars are clocking over 15 years old they need a little extra care. Unless yours has been a garage queen only out on dry days it will probably look the same.

Here are some photos, the long rusted strip on the back of the bumper and the broken brackets are what is left. Loads of shards of rust tucked under the polystyrene that I cleared out. The bracket has a 3m double sided sticky tape backing

 

[D Walker]

Spartacus (Martyn) should be able to CAD it for you...

 

[Gp79]

Good work, my job list for this winter just got longer!

 

[Charlesmaserati426]

Definitely something I will be doing before the weather gets bad! Is there a way to prevent the water pooling in there to prevent surface rust?

 

[FIFTY]

Not sure. Replacing it with stainless steel that has been painted is the best way to ensure longevity.

 

[Charlesmaserati426]

I had a spare few hours which I planned to do some cosmetic clean up, so thought I’d take a look at mine.... and my bracket flaked away in my hands lol. My brace doesn’t seem as bad as yours did in the pics, but I rubbed it down and applied a couple of coats and it looks a lot healthier. I just need to fab up a bracket. I’m probably going to go with an aluminium alloy of a similar spec to help prevent with the rust build up. Unsure how I’ll prevent rust build up from the bolts since the water is pooling there, that’s my next step.

 

[FIFTY]

I had a spare few hours which I planned to do some cosmetic clean up, so thought I’d take a look at mine.... and my bracket flaked away in my hands lol. My brace doesn’t seem as bad as yours did in the pics, but I rubbed it down and applied a couple of coats and it looks a lot healthier. I just need to fab up a bracket. I’m probably going to go with an aluminium alloy of a similar spec to help prevent with the rust build up. Unsure how I’ll prevent rust build up from the bolts since the water is pooling there, that’s my next step.

I can't see how it can be sealed or drainage added without making things worse I guess a new bracket is in order every time the rads is done. Aluminium is not a bad idea - it will probably still oxidise eventually but that will not spread onto the brace... Thinking about it I could probably manage to make one from aluminium using a length of L shape profile and some flat strips but the vertical section will have to be bolted onto the horizontal which will be a bit crude... I am sure that I will be making the engineers on here cringe at the prospect

 

[conaero]

Personally I would just get another one from Stu or DA and paint/waxoil the area. If it lasts another 15 years I would say thats good enough.

 

[FIFTY]

@conaero I will send them a message but I'm not optimistic about availability as the bracket is not a separate item on the expanded diagram on ES for the front bumper assembly - so we are relying on the breaker separating the bracket from an intact front bumper

 

[Charlesmaserati426]

I can't see how it can be sealed or drainage added without making things worse I guess a new bracket is in order every time the rads is done. Aluminium is not a bad idea - it will probably still oxidise eventually but that will not spread onto the brace... Thinking about it I could probably manage to make one from aluminium using a length of L shape profile and some flat strips but the vertical section will have to be bolted onto the horizontal which will be a bit crude... I am sure that I will be making the engineers on here cringe at the prospect

I’m waiting to hear from my friend who’s an engineer/metallurgist as to what spec, he said it shouldn’t be a problem. But mentioned it may be an idea to possibly look at changing the bolts. Even then it could be running from elsewhere. Depends how anal you want to get, I’ve always wanted this car since it’s launch haha so I plan on keeping it for the long haul! Just wish I could figure out where the waters getting in. If it is just a case of it pooling inside when driving in the rain, i would assume that there has to be a way of deflecting it elsewhere.

 

[FIFTY]

It could be running down the bolts and the bracket but I reckon it is from when rain water is being drawn into the cowling of the radiators and then splashes back onto the polystyrene and bracket then pooling slightly underneath due to the angle of the plastic.

 

[FIFTY]

I ordered 1m of 40 x 40 x 3mm 304 grade stainless steel angle or L profile and 500mm of 30 x 3mm flat bar... wish me luck cutting drilling and bending it with my junior hack saw and crappy drill (don't have a work bench + vice either). The plan is to bolt it all together I will offer up the new verticals to what is left of the original brackets right at the top which attaches onto the subframe as recreating that section is beyond my abilities - once it is all cut and drilled I will wet spray it with primer and satin black top coat to prevent surface rust. I will take some photos once done (or not if I need to hide my shame)

 

[Corranga]

Good luck, look forward to the results.

I presume there is a bolt hole in the middle where it's rusted through?

 

[Charlesmaserati426]

Yeah that’s not going to be fun cutting stainless with no vice like that! My friend bringing me my piece tonight. Going to mark up, angle grind out and flap disc off the burrs. Anyone you could borrow a grinder from? Good luck!

 

[FIFTY]

I went to collect mine from my parents house and it was "lost" searched high and low and I suspect that my dad sold it because it was sitting there unused for several years

I could hire a 225mm diameter angle grinder from HSS for only £7 but that is massive; I'll probably end up cutting into the drive! The one I want is the cordless Milwaukee brushless grinder but I cannot afford it until next month (already spent way too much on parts and tools this month plus I am getting married in a month)

 

[FIFTY]

Good luck, look forward to the results.

I presume there is a bolt hole in the middle where it's rusted through?

Bolt hole through the bumper? The only thing in that area are the rivets that hold the number plate holder in place

 

[Corranga]

Bolt hole through the bumper? The only thing in that area are the rivets that hold the number plate holder in place

That makes sense, I couldn't figure out how the bracket was held to the bumper

 

[Charlesmaserati426]

That is a little on the large side! How are you planning on holding it? Could rig something up with some old pallets, nuts and bolts if you have access to them?

That’s understandable, weddings aren’t cheap! Definitely something for you to invest in the future!

 

[FIFTY]

That makes sense, I couldn't figure out how the bracket was held to the bumper

The number plate holder is held in by rivets... the bracket in question does not use fixings to attach to the bumper - what was left of it was held in place with double sided tape so a combination of that and the angular profile acting as a ledge - however that had totally disintegrated

The bracket is difficult to describe so I have made an extremely crude drawing on MS paint for you showing the side profile and a snip from a photo of the back of the bumper, the vertical strips running up to the subframe mount follow the channels highlighted in yellow

 

[FIFTY]

That is a little on the large side! How are you planning on holding it? Could rig something up with some old pallets, nuts and bolts if you have access to them?

That’s understandable, weddings aren’t cheap! Definitely something for you to invest in the future!

Good idea I could pick up a pallet from the warehouse at work. I have a 4" G clamp and can always pick up another one

Plus we are going to use the 4200 as our wedding car and take it for a tour of Italy all the way down to Pompeii/Amalfi for the honeymoon so this is all prep for that (new rads, thermostat and temp sensor to go in on Saturday, refit bumper on Sunday if I'm up to it.