C3 Bumper Cover Install - Rubber Bumper Blues

The new urethane bumper cover from Zip came well protected. The new cover was made from the factory molds and uses a more advanced urethane compound that is less likely to sag and wrinkle as it ages. Fiberglass covers are another option and are described in the accompanying sidebar.

The exterior surface finish on the urethane cover was excellent. There were no pits, sand scratches, or blemishes. The mold flashing was well trimmed, and the exterior surfaces were primed.

Order the upper retainer, and both left and right side retainers for the bumper cover. Most Corvette owners think their car is rare, but it would be really rare if the old retainers were still in good shape after decades exposed to the elements.

The studs can become loose in the upper retainer strip, just like the originals. JB Weld cured the problem. Trim any cement after it dries because the retainer fits tightly against the cover and excess cement may cause dimples in the cover that will be visible after painting.

This project is ripe for "while you're there..." side jobs. The lower front valence was ready for replacement after losing a bout with a 5-gallon bucket of spackle that dropped off a truck. It's a good time to consider replacement or refurbishing of the signal lights and grilles.

Begin by jacking up the front and removing the grilles. This opens up access for the bolts and screws of the lower valence and the spoiler. Spray penetrating oil or WD-40 on the exposed threads of all the bolts and screws. Life will be easier if you can save and reuse the original fasteners.

Be alert for different screws in different locations. The factory used a number of different fasteners, and if any subsequent repair work was done, that greatly increases the likelihood of a mixture of screws. A hex-head sheetmetal screw is on the outboard end of the spoiler, while a machine screw occupies the hole right next to it.

The different screws you encounter can look pretty similar. With its tapered thread, the machine screw on the left looks a lot like the sheetmetal screw on the right. On older Corvettes, the fasteners you encounter are like a box of chocolates.

Take note of the different types of trapped washers on the bolts, too. The bolts with larger washers are used for the large holes in the lower valence, while the bolts with the smaller holes fit in the indented or recessed locations.

Removal of the lower valence and spoiler should be easy if the fasteners aren't rusty. You'll appreciate how much room you have to work here when it's time to reach inside to remove the bumper cover nuts.

If replacing or refinishing the lower front valence, pry the clips off now and bag them. It's easy to forget and throw the old panel away with the clips still attached.

Closely compare each replacement part with the original. Check the overall dimensions and shape and the size and location of every hole. It's much better to learn of any problems now instead of after repainting or during assembly.