Bumperettes/Nerfs | 356 Speedster, 550 Spyder, Replica, Automotive Community

Rich Drewek Supporting Member

Hey guys, I've been kicking this idea around for a number of months. I want to recreate my existing "bumperettes" as I call them and turn them into "nerf" bars. I've been exploring having them machined but that is proving to be cost prohibitive. Now, I might have someone interested in casting these and then doing some grinding and polishing to finish them properly. Depending on cost, is there anyone else out there that would like to go in on this? I'm thinking that if I cast 4, why not do more and maybe get the overall cost down. I hope to discuss this with the foundry tomorrow and have a better idea of a price. The photos are Photoshopped but give you a pretty clear idea of size and appearance.
New attaching brackets would need to be fabricated, but that's the easy part. Any interest?

3/20/129:29 AM

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Rich Drewek Supporting Member

Hey guys, I've been kicking this idea around for a number of months. I want to recreate my existing "bumperettes" as I call them and turn them into "nerf" bars. I've been exploring having them machined but that is proving to be cost prohibitive. Now, I might have someone interested in casting these and then doing some grinding and polishing to finish them properly. Depending on cost, is there anyone else out there that would like to go in on this? I'm thinking that if I cast 4, why not do more and maybe get the overall cost down. I hope to discuss this with the foundry tomorrow and have a better idea of a price. The photos are Photoshopped but give you a pretty clear idea of size and appearance.
New attaching brackets would need to be fabricated, but that's the easy part. Any interest?

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Carl Berry CT.

Rich, Neat idea. I like the look...You're a dangerous dude with Photoshop.

Have you considered adapting VW overriders (bumperettes?) They're plentiful and cheap.

3/20/1211:00 AM

Rich Drewek Supporting Member

Not sure I'm aware of which you speak, Carl.

3/20/1211:04 AM

Bob: IM S62016 Intermeccanica S6 Supporting Member

Good idea, but they look a little too heavy.

How about this:

http://www.emorymotorsports.com/images/stories/outlawimages/Photo8_4-30-98_10_37_AM.jpg

3/20/1211:31 AM

Rich Drewek Supporting Member

Here's another look at the rear end.

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3/20/1211:33 AM

Rich Drewek Supporting Member

Robert, I think the Emory's look a little wimpy. Beauty is in the eye of the beholder.

3/20/1211:34 AM

Rich Drewek Supporting Member

These would be the same size as the existing "bumperettes" that are on the bumpers now.

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3/20/1211:44 AM

Bob: IM S62016 Intermeccanica S6 Supporting Member

Nice looking car!

Yes, it's whatever you like with these cars.

Rich Drewek Supporting Member

Thanks Robert, and yours is real sweet as well. Sorry I'll miss seeing yours in Carlisle in that I can't make the gathering this year.

Rich Drewek Supporting Member

So I started the process of casting these things. Reworked the original with some modeling clay and then built a small box to hold the mold. Poured that today and will now need to wait for that to set before I can crack open the box. Then I'll pop that original model piece out of the mold which will allow me to pour some wax copies. Those wax copies will then be invested into another mold and then cast in aluminum. In the end, there will be some grinding and polishing. Hopefully all this pays off in the end. I'm still ready to make more for someone else who might be interested. Let me know if you're interested.

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3/28/1212:00 PM

Rich Drewek Supporting Member

Day 2 of the casting process...6 hours worth of applying wax to the mold to create 4 copies. Next step will be a little trimming of the wax pieces before investment casting (lost wax casting). I'm going to see if I can get them cast at my alma mater, just thought of that possibility today as I was making the wax copies. Might get lucky and make this much less expensive. I have to admit these are looking real nice! If I get real energetic, I might just make 4 more copies so I could have a second set waiting in the wings.

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Rich Drewek Supporting Member

So, yesterday I mailed off the final wax pieces for the casting to the foundry I'll be using and they arrived in tack today already. They have given me an initial 30-day turnaround time. I'm anxious to see how nice of a surface finish I'll get on the cast piece since I don't have a buffing wheel. Anyone out there willing to help out in that process...raise your hand now, thanks. Here's last week's photo of the final surface. The screws have definitely been removed already, they were used to dip the models in a bath of hot wax, gradually building up the smooth surface you see here.

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5/3/121:33 PM

Lane AndersonMt. Pleasant, SC Supporting Member

I know Mike Lempert has a buffing wheel. I might be able to get him to show me how to use it. What sort of help are you looking for?

5/3/126:30 PM

Rich Drewek Supporting Member

Well Lane, when these wax pieces magically turn into aluminum soon, I want to bring the surface up to a shine similar to the originals. I'm pretty sure the cast pieces will come out fairly rough and there will some grinding, polishing and buffing needed. Machines help. I have contacted a local metal finishing place and right now their estimate seems a little steep, but then they have only seen my preliminary photos so far. Once I get the final pieces I'll know more what's going to be needed.

5/3/127:44 PM

Rich Drewek Supporting Member

Pretty quick turnaround at the foundry that I ended up finding and using. Now some fitting to the body profile with grinding, polishing, drilling and tapping the mounting plug and finally mounting. They look a little rough now, but after the elbow grease is applied, I think I'm going to like the final results.

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5/18/1210:33 PM

MangoSmoothie.ca

right on Rich!

Good on you for makeing something nobody has because you have a vision.

what sort of bracket you planning

Rich Drewek Supporting Member

Paul, yup a nice tight contour fit is the plan, maybe about one inch of the body. A simple, aluminum L-bracket mounted in the stock Beck position to the frame. Drill and tap that stub on cast into the part with a single threaded rod similar to the original will bolt onto the bracket. Should be pretty straight forward, even for a numbskull like me. Sure wish I had a nice big, loose belt sander and buffing wheel.
I'll see, if this gets too labor intensive, I may job the task out to a finisher who could probably make quick work on these. I'd like them completed in time for our Midwestern Drive-In/ Cory Pit Stop in Peoria in about 4 weeks down the line.

5/19/1210:16 AM

Rich Drewek Supporting Member

The slow tedious process of grinding has begun. Proper tools would make this part a heck of a lot easier.

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Panhandle Bob'57 VS Supporting Member

I can only guess the time you are putting into these!

They are really coming together, and I am anxious to see them at the Drive-In / Cory Pit Stop in Peoria.

Really cool!

Bob

5/22/1212:06 PM

Rich Drewek Supporting Member

Bob, the plan is to have them completed by Peoria Time...that should give you a rough idea of how much MORE time I am putting into these.
If I didn't like them so much I would have quit a long time ago. Then there's the money factor, but I won't go there. Just bought a 4.5" grinding wheel today, always needed one, add that to the tally?

Rich Drewek Supporting Member

Another long day of cutting and grinding, they're getting there slowly but surely. A high polish is still a ways off.

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Rich Drewek Supporting Member

Spent some more hours on bringing up the sheen on the bumperettes today.
Two almost complete and two more to do. My brackets should be complete soon and after a trip out of town next week, I should be able to mount them. I'm pretty pleased with the results.

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6/1/127:24 PM

Bill Prout

Looking good!

6/1/128:17 PM

Rich Drewek Supporting Member

After three months of really hard work, the "bumperettes" are completed and mounted to my car. It took a lot more effort than I originally planned, but they are completed and I like the results. I still might fine tune the attachment points, but for now I need to drive.

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6/15/1210:52 AM

bt Supporting Member

Surprised I had not seen this thread before. Those look great!! They look a lot better than stock nerf bars. Kudos to you.

6/15/1211:19 AM

ALB

Looks good!

6/15/1211:21 AM

MangoSmoothie.ca

Good work - those look like factory parts

6/15/1211:31 AM

Rich Drewek Supporting Member

Thanks guys, now I can get busy and clean the bugs off the nose. Should be easier than making the bumperettes.

Lane AndersonMt. Pleasant, SC Supporting Member

Originally Posted by bt:

Surprised I had not seen this thread before. Those look great!! They look a lot better than stock nerf bars. Kudos to you.

No kidding. Nice work, Rich.

MusbJim'14 VS SoCal Supporting Member

Nice work, Rich!

6/16/1211:29 AM

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