C3 Bumper Cover Install - Rubber Bumper Blues

Check the fit on both sides at the fenders, too. There's only so much you can do at this stage, but at least be sure the holes are sufficiently elongated to achieve the best fit possible between the bumper cover and the body panels.

Elongate the holes if needed to enable the cover to be moved up, down, or to one side. A small rat-tail file or a Dremel tool are the best tools here. If the holes are significantly enlarged, small washers should be used under the nuts for the retainer.

A coat of POR 15 will keep the retainers from rusting, and provide a little help keeping the studs tight in the upper retainer. Two cautions: (1) make sure the POR 15 doesn't get on the threads-it's like cement, and (2) wear gloves or you'll be sporting POR 15 spots for days.

Install all the retainers to make sure they fit properly and to hold the urethane cover in its proper shape. Without the retainers, the bumper cover is too flexible for painting off the car. Mask all the exposed threads on the retainer studs.

If you're in Florida, California, or the Atlanta area, Carsmetics is an option for painting the bumper. They specialize in small repairs and apply DuPont paint that comes with a lifetime warranty (good at any DuPont AOQ shop). The cost was $350 for the bumper cover and lower valence (both painted off the car).

This shows how brittle the old cover had become-it broke in two when dropped in thick grass. The cover has one last service to perform. It will be used as a spray test panel by the painter to make sure the color match is acceptable.

While the bumper is being painted, it's a good time for the "while I'm there..." projects, like refinishing the screws and grilles in semi-gloss black.

With the bumper cover and bar removed, there was easy access for replacing the top panel support bracket and the energy-absorbing bolts. The large square die on the bolt is slightly smaller than the bolt shaft diameter. When the bumper bar is forced rearward during an impact, the die is pushed down the shaft stretching and extruding it to safely absorb some of the impact.

Rivet the bumper cover to the lower retainer with 3/16 aluminum rivets with large heads. This can be done before painting, or after to keep the rivet head natural. The rivet heads will be covered by the lower valance panel.

After the bumper cover is installed, the job is nearly done. It's a perfect time to replace a ragged spoiler. When trying to order a spoiler, it helps to know that it's also called an air dam or air deflector.

The last step is installation of the grille and lamp assemblies. The holes in the mounting brackets allow a little adjustment. If more is needed, elongate the holes. Bending the brackets risks cracking paint or fiberglass because they are riveted to the fenders.

New bumper cover install completed-sleek, shiny, looking fine and ready for at least another twenty years. Nip/Tuck couldn't do a better looking nose job.