Phase two of MINI Makeover ( phase 1 was vented A-Panels ) is new Aero Bumper with DIY Molded Brake Ducts and more of a form fit Splitter. Made my own wood molds to vacuum form the brake ducts, formed the Lexan at work. Used sheet metal brake to bend Lexan splitter to better conform to bottom of bumper. Reused splitter braces but took off the vinyl/paint from before. Took off old driving lights and put on some new ones. Though I need to raise them up alittle and wire them in yet.. Tested 4 different colors of tint for them and picked the green just to be different. Can always switch colors and go without a color. Here is one of the molds, ( there is a right and a left ) fitted into a test bumper, and a shot of them rough vs trimmed to fit.
Thanks ya'll... Nope didn't own a vacu-form as a kid but did recently build a small vacu-form to use for this project but ended up getting them "pulled" at work..
Stole the idea from one of the MINI vendors who used to sell them as magnets.. I got access to a used set and made a computer program to closely match and cut it out on the vinyl plotter.
Nice job Bryan! I do like that small bend in the splitter looks good. Did you use your original pattern or did you have to adjust for the bend?
Used the same pattern. With those bend it did shrink the over-all length by about 1/8'' not enough to worry with, plus I have been playing with the width of it over the years anyway.