Modding a TRD rear lip

[bman365]

I bought this fiberglass trd rear from a guy on here for this specific reason; It's easier for me to mess with fiberglass than plastic

It's a pretty rough piece to start out with... It has cracks, pieces broke off, and now..holes. It's in three pieces so it would help with shipping and it was already broke at the exhaust part.

So even with it in three parts, it still didn't fit that great. All the corners were built up too much and didn't allow it to sit flush so all that was ground down on the back.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4115-1.jpg

I cut out the fins so I can smooth those sections out. They are cut right at the bottom of the fins where it starts to flatten out with the rest of the lip, this will help with less sanding later. I may add some fiberglass to the side pieces where the fins were removed to bring that section down and flow it better instead of having that weird little curve.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4113.jpg

More to come tomorrow or this weekend.

[yodaddyguido]

hoping for the best man :thumbup:

[Gootz311]

:popcorn:

[CRBCelica]

i want to do this too, subscribed!

[Joey03_VVT-I]

Wow...good luck! :eatpop:

[bman365]

Worked on it a little today but had to run somewhere, so I will be glassing it tomorrow.

First step today was to tape up the bumper where I would be glassing the parts together. This also helps from scratching up the bumper. I started to tape up the whole bottom half of the bumper, but it wasn't needed.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4119.jpg

Next I ground down the ends where I will be adding fiberglass to.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4118.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4117.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4116.jpg

When they make these parts from a mold, the first thing they spray in is gelcoat, which is usually what you see when you get a fiberglass part because they are black, green, yellow, white, etc. This one had white gelcoat, and a lot of it! The reason it broke at the exhaust part is because there wasn't any fiberglass besides a paper-thin piece, the rest was gelcoat. So all the gelcoat was ground down to the fiberglass so that, 1 - I can add quite a bit of fiberglass and build it back up to the original thickness and 2 - I think it will bond better if it's glass to glass so it will be a stronger repair.

......and more tomorrow.

[fabez14]

good luck man

[mrluilou]

good luck !

[bman365]

Next step today was to fit the pieces back on the bumper. I measured at the top of the trd lip to the line in the bumper to make sure it was parallel from end to end. I measured ~7 1/8" - 7 1/4" all the way across, so it's close enough. So I secured the pieces on the bumper with tape and clamps ( I didn't want to remove the wheels to put in screws).
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4126.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4127.jpg

Next, I measured the gap and how much I ground out so I can cut my fiberglass to size. This is 1.5oz chop mat but you can seperate it and get thinner pieces out of it, so each piece is about .5oz after I done that. Thinner piece goes around sharp angles better and easy to wet out.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4120.jpg

Next, I poured about 3oz of polyester resin in a mixing cup and added 25 drops of hardener (mekp). The real ratio is 10 drops per oz of resin, but I was accounting for how hot it was today to give me some more time to work with it. Each oz of resin should wet out a square foot of 1 oz mat, so I had a little left over so I came out about right.

Next is fiberglassing the parts together. Brush some resin on the parts, lay one fiberglass layer down then wet out with resin. Continue this until all the layers are down, but don't over do it on the resin..just enough to wet out the fiberglass.

The exhaust part had too sharp of an angle so the glass wouldn't wrap around, I'll just get this after these layers cure.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4130.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4128.jpg

So I wait for the glass to cure enough for me to cut it and lay some on the bottom of the exhaust opening.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4131.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4132.jpg

[fabez14]

very cool
that youre doing this yourself, great progress
and im subscribing!

[2KGTrd]

looks good.
i can't wait to see what you do with my oem front!

[bman365]

looks good.
i can't wait to see what you do with my oem front!

That's going to be later, probably the last thing I do. Next is the fenders.

[bman365]

Let it cure for a hour or two and pulled it...
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4134.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4135.jpg

I started on my fenders so I didn't start on the backside yet, I might do that tomorrow or later in the week.

[Gootz311]

Wait a min....I thought you were making end caps with this piece. So all your doing is shaving the fangs off ?

[bman365]

Just shaving the fins off, not making end caps (that's why I cut the fins off the center part too).

Send me a rear and I'll make end caps out of them :)

[Gootz311]

I gotcha, so like this.....

http://i31.tinypic.com/2comt7t.jpg

Saw this rear in person and it looks pretty sick.
Im good on the end caps, I like the rear lip I have. :gap:

[crystalalien87]

^^^Me want that so bad :(

[bman365]

I gotcha, so like this.....

http://i31.tinypic.com/2comt7t.jpg

Saw this rear in person and it looks pretty sick.
Im good on the end caps, I like the rear lip I have. :gap:

I didn't know if you had the end caps or not..

[fabez14]

molly end caps! :rofl:

[Gootz311]

lol^

Yeh your orange now! Ive noticed alot of you noobs popping up. :chuckles:

Now start going to the supporters only section! Its been dead in there.

...sorry to go ot.

[fabez14]

will do
yup im orange!

[ikhaffaji]

dude thats my old TRD rear that broke in shipment to yodaddyguido!!!

[yodaddyguido]

dude thats my old TRD rear that broke in shipment to yodaddyguido!!!

yup. fkin greyhound. lol i shipped fedex :wiggle:

[2KGTrd]

that rear looks sick.
I might do that to my trd rear now instead of replacing it!!!

bman what's your plans for the front?
Sorry I haven't sent you the pics yet I've been busy rebuilding my motor.

[bman365]

that rear looks sick.
I might do that to my trd rear now instead of replacing it!!!

bman what's your plans for the front?
Sorry I haven't sent you the pics yet I've been busy rebuilding my motor.

The front won't be revealed until I'm done.

[Joey03_VVT-I]

:eatpop:-Interesting
Can't wait for more pics.

[CRBCelica]

sexy

[bman365]

So, same procedure again - grind down area, cut chop mat, mix resin and apply. Which looks like so..
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4144.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4145.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4146.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4148.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4147.jpg

The holes I cut out really need to be glassed in because the whole piece is weak and wants to break..So that is next and then to reinforce the exhaust area some more.

[Loser_guy]

I did the same thing to my wing's west lip after dragging one side of down the road for 15 miles. I used 3m plastic repair, a little bondo, and lots of heavy bodied primer.

http://i32.photobucket.com/albums/d49/loser_guy/DSC_0001.jpg
http://i32.photobucket.com/albums/d49/loser_guy/DSC_0002.jpg
http://i32.photobucket.com/albums/d49/loser_guy/DSC_0003.jpg
http://i32.photobucket.com/albums/d49/loser_guy/DSC_0004.jpg

Don't have any pictures of it painted, apparently... but I still haven't installed the thing (after a about a year) because the exhaust I bought is so off center I can't even get it on there.

[bman365]

Those pictures weren't neccessary in this thread..^

Anyways...filled the holes up.

Grind down the area, tape up the front side, cut mat for backside and apply resin..
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4149.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4151.jpg

The left side is broke, so I have to fix that before I can fill the holes.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4150.jpg

[CRBCelica]

did you fill the holes with bondo?

[bman365]

No....I said what I did. Bondo doesn't add strength, which is usually what people get wrong about it. Bondo is body filler..it's just to get small imperfections out that's 1/8" or less.

I only used fiberglass chop mat..body filler comes last when I about have the surface even.

[2KGTrd]

^^the other post used an abs filler and then added bondo on top of it.
....Another post that confused the hell outta the lot.

Sorry bout your pics been busy finishing up fs deals preceding yours.
Also how else do you plan on reinforcing the lip? it seems like it needs it.
Would adding something like an aluminum piece in the center for extra strength work?

[bman365]

^^the other post used an abs filler and then added bondo on top of it.
....Another post that confused the hell outta the lot.

Sorry bout your pics been busy finishing up fs deals preceding yours.
Also how else do you plan on reinforcing the lip? it seems like it needs it.
Would adding something like an aluminum piece in the center for extra strength work?
Yeah his post shouldn't have even been in this thread, it just causes confusion.

Once it's on the car, the center is supported by the bumper. More fiberglass could be added, but it doesn't need to be that strong. If I add anymore to the lip, it will not fit right up against the bumper.

[bman365]

So removed tape and it looks like so.....pretty even but needs a layer added.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4153.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4154.jpg

Fixed the broken parts today. Taped up the backside on the one I have pinned down and I CA glued the other one together so I can lay some glass across it.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4156.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4155.jpg
Once these set up, it will be just like the other holes. Then to fix some cracks in the rest of the lip.

[lilmexicanoboi]

officially subscribed. this kind of work inspires me to come up with new ideas ;)

[zzt231 gr]

Wow,good job!

[bman365]

Thanks!

So finished up filling the backside. The broken pieces cured really fast sitting in the sun so I could grind them back down in no time.
(I'll insert image later, photobucket has failed me)

Well that's all for today, maybe tomorrow I will update with some more.

[Loser_guy]

Wasn't intended on causing confusion, just showing how I did it with my plastic lip since plastic can't be repaired with fiber glass like your's in case there are other people insane enough to cut their lip up like I did.

Only thing I'd change is not using body filler. Only reason I did was because the edge of the 3m plastic repair kept showing up while sanding the primer thanks to temperature change and the primer drying down into it. Where the lip flexes so much it has spider-webbed the paint some, but it's on the underside.

[bman365]

A little bit more..
Ground down to the fiberglass and ground out the air pockets.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4158.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4159.jpg

I layed some glass on it but didn't take a pic..but you get the idea.

[Joey03_VVT-I]

HAha...wow...that's simply amazing. Good job and can't wait to see the finished work. :thumbup:

[bman365]

Yeah finished work will be a little while. I still have to fix some parts that are broken off and then sand the bish.

[bman365]

Ok, well I have been slacking with this and have been preoccupied with some other things..but here is progress.

So..like i mentioned earlier, I didn't like the shape of the lip after you cut the fins off. Which looks like so..
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4210.jpg

I hate the dip in, so I'm filling it in.

I got green foam, which is floral foam for flowers and all that. Reason for this is that it doesn't melt when resin is on it, so you can fiberglass over this and won't lose shape. Also I found out it sands and cuts down super super easy. It was $4 for a 6 pack of the little blocks..which are the size of standard red bricks.

I cut the blocks down so they can go with the curve of the lip and hot glue them down. I only cut them so they were high enough to sand down to get my shape, didn't need the whole height of the original block.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4205.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4204.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4203.jpg

Next I used an auto body rasp..I have two different ones. I didn't feel like pulling out the sander tonight because it would just get this stuff everywhere, so I cut it down with these. They store all the shavings inside of them so every once and a while you just dump it out.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4206.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4207.jpg
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4208.jpg

I'm close to the shape I want, so I'll finish the rest by sanding later.
http://i115.photobucket.com/albums/n313/bman365/trd%20front/CIMG4209.jpg

[TRD01GT]

crazy man

[Pool Playen Bob]

man. you do awesome work.i'm very impressed.

[lilmexicanoboi]

:headbang:


its coming out great! that foam idea was genius!

[JO_CELICA]

looking good!

[InsolentMinx]

love the foam idea!

how's it coming along?

[bman365]

It's been put on hold again..trying to catch up on some other stuff.

[lajlijthoj]

Waiting. I want this.

[bman365]

I'll be back on this when I get time..and when it gets warm. I have a whole kit now so it will be completed.

[Joey03_VVT-I]

Wow....update? :eatpop:

[monkeyb01]

BUMPING THIS THREAD!

I decided to bump this thread because i bought these endcaps of bman365. I decided to show the progress and i try to finish these off. I received the endcaps on Tuesday and wanted to get a jump on it quickly. I wanted to make something similar to molly, sports m, and vizage end caps. Here is what i have done so far with the endcaps:

Received the endcaps with the edges with an opening for the midblade. I had to cover up that hold or else it would look funky.(Didnt really take any pics when i first started to fiberglass and my gloves were sticky from the resin.) What i did was used a piece of cardboard to create a "wall" for me to lay down the fiberglass. I cut the cardboard so it curved with the bottom portion of the bumper. Then i laid down about 3-4 layers of fiberglass. Once when it dried, i started my sanding. Here is how it looked like before i started.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0519.jpg

After i finished fiberglassing a closure part and sanding it, i started to bondo. Once when the bondo dried, MORE sanding was involved. I was lucky that this wasnt a big project or else sanding would be PITA. Heres a pic of a comparison between the one i started with and the one i didnt:

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0520.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0521.jpg

I just did a quick mount to the car to see if the closed portion curved with the bumper and it was about 90%. Heres a quick pic of test fit: (This was when i didnt sand down the bondo yet)

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0518.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0515.jpg

In this pic it was just hanging down, thats why there was a big gap between the bumper and endcap:

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0516.jpg

[Joey03_VVT-I]

OHhhh...cool. Good luck with that project bro.
I'm looking forward in seeing it finished. :thumbup:

[bman365]

Good luck with it man.

[lilmexicanoboi]

I'm interested :)

Please... DO go on :thumbup:

[monkeyb01]

Good luck with it man.

OHhhh...cool. Good luck with that project bro.
I'm looking forward in seeing it finished. :thumbup:

I'm interested :)

Please... DO go on :thumbup:

Thanks guys.

Here is what i got done so far today. I started with the left side of the endcap and it was the same process i did with the right endcap. I first fitted the endcap to see which extra part i had to cut off.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0524.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0525.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0528.jpg

I just did a little bit more trimming and now it was for my cardboard method to close up the opening.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0529.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0530.jpg

I started to trim the cardboard a bit so it could curve with the bottom portion of the bumper.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0531.jpg

After i finished trimming the cardboard, i began to mix the resign and laid down the fiberglass matt.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0533.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0534.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0535.jpg

After the fiberglass dried up, i started to trim down the fiberglass again. (pics comparing it to the other endcap i did)

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0536.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0537.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0538.jpg

Now im waiting for the fiberglass to fully harden up so i can start to sand and then after i sand it down, ima start to bondo.

[monkeyb01]

UPDATE!

Finally the fiberglass hardened enough for me to start sanding. As i sanded and sanded i finally got the glass smooth enough for me to lay a fresh coat of bondo on it. I didnt take any pictures of me sanding or anything cause who wants to see someone sand :chuckles: . Here as i wait for the bondo to dry. The left endcap was in a more worse shape than the right endcap so this one required more bondo.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0539.jpg

Once when the bondo dried, I SANDED SOME MORE. Forgot how many sandpaper i went through but i swear my hands has gotten stronger.

Here are some pictures that i took when i mounted both endcaps on the car. Now im thinking of ideas of creating brackets for the bottom piece to hold down the endcaps so it doesnt go flying off at 70+ mph.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0551.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0553.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0554.jpg

Sorry for all the sh1tty pictures. These were all taken with my phone. I probably still have just a little more bondo and more sanding and these are good to start painting.

[lilmexicanoboi]

I'm really liking the progress. Nice work! I'm looking forward to the end result for sure :gap:

ow im thinking of ideas of creating brackets for the bottom piece to hold down the endcaps so it doesnt go flying off at 70+ mph.

The actual Molly end caps has the part closest to the wheels closed off so it's not like a air scoop or anything. It "hugs" around the rear bumper and the car chassis. Maybe you can incorporate something like that into them? :shrugs: Just a though...

[gts_02]

Looks good so far man! Keep it up! :thumbup:

[monkeyb01]

I'm really liking the progress. Nice work! I'm looking forward to the end result for sure :gap:

The actual Molly end caps has the part closest to the wheels closed off so it's not like a air scoop or anything. It "hugs" around the rear bumper and the car chassis. Maybe you can incorporate something like that into them? :shrugs: Just a though...

Are you talking about this part right here? Here are some pics of the of trd endcaps. This is the part closest to the tire so this part hugs the bumper too.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0558.jpg
http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0555.jpg

Heres a pic from under.

http://i257.photobucket.com/albums/hh228/monkeyb01/IMAG0561.jpg

[lilmexicanoboi]

Oh! Ha! Fail. I forgot that the TRD rear has that. I thought you were making these from scratch at the moment I posted :faint:

Carry on :)

[monkeyb01]

LOL. If i could make these by scratch, i would made more, became a vendor, and sold some HAHA

[lilmexicanoboi]

You can make a mold ;)

[monkeyb01]

I will later when i finish my rear diffuser ;) . Hopefully i can finish it by the end of this year. SOmething clean and simple like varis

[Joey03_VVT-I]

:thumbup:-NIIiiiiiiice! Keep it up bro!
The end result should look something like this? :drool:
http://memimage.cardomain.com/ride_images/3/2696/3321/31739160037_large.jpg

[bboiicelica]

Any update?

[monkeyb01]

Any update?

I forgot about this thread. I have the endcaps sitting in my garage waiting for pInt. Im deciding wether i should shave off the extra loose piece at the bottom

[InsolentMinx]

:popcorn:

yellowchinaman over on CCUK has been making these... should be done at the end of Jan.

he needs a few more tweaks and a car to fit them to for pics, but they look good...

http://www.celica-club.co.uk/forum/index.php?/topic/132058-gen-7-m-sport-spats/

[R I C H I E]

Should look dope.

http://www.celica-club.co.uk/forum/index.php?/topic/132058-gen-7-m-sport-spats/

Post pics, link requires registration.

[InsolentMinx]

pics aren't great as it's a bit dark and they're just a mock-up on a rear bumper, but this guy does top work. He has a perfect urethane replica of the C-One lip, fibreglass C-One hood scoop, TRD rear valance and TRD spoiler.

http://i417.photobucket.com/albums/pp253/yellowchinaman/DSCN4710.jpg
http://i417.photobucket.com/albums/pp253/yellowchinaman/DSCN4706.jpg
http://i417.photobucket.com/albums/pp253/yellowchinaman/DSCN4698.jpg
http://i417.photobucket.com/albums/pp253/yellowchinaman/DSCN4703.jpg

[monkeyb01]

Well the Holidays has just passed and things has started to settle down, im about to start painting.

Had to do a little bit of more bondo to fill up the little details

http://i257.photobucket.com/albums/hh228/monkeyb01/IMG_20120126_225400.jpg

[monkeyb01]

My only concern about install this is that once when i hop onto the road, im afraid it might catch a little bit of wind on the underside of the endcaps and end of having it fly off my car