I managed to finish both custom Aluminum Porsche bumperettes this week and I love them! Above all, this was a fun project working with Aluminum for a change from steel. Although not a dramatically different from stock, my car appears just a little different than everyone elses.
I wanted the bumperettes to be smaller than stock and also lightweight. Porsche’s are notoriously heavy in the rear already, so anything I can do to lighten the load behind the rear wheels is a major plus!
CNC Machine Time!
After cardboard template round three and four I came up with a shape I liked. The new bumperette design doesn’t extend all the way down to the bottom edge of the bumper. In particular, I feel this makes the car look wider as the lower edge isn’t broken up by the stock bumperettes. Next, I programmed the CNC machine to cut the shape out of .125″ aluminum sheet.
Videos of Aluminum Porsche Bumperettes
The work is broken up into two videos. The first video highlights the design, trial fits and CNC machining the parts from a flat sheet.
The second video describes the custom tooling needed to radius the edges some prior to welding all the pieces together into a box shape.
I wanted the junction of the flat plates to have a similar radius as the factory bumperettes. In order to achieve this, I had to roll the edge of each flat plate. Next, I corner welded the plates with my TIG of course, Then I filed the shape to the approximate factory radius. Do you like it? On one hand some folks are Porsche purists and the other hand they hot rodders. For example, I’m somewhere in the middle???? What?
Thanks for watching and contact me if you have any comments or suggestions!