DIY - Repair STi / Ultrex lip

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DIY - Repair STi / Ultrex lip

Postby cruisn » Sat Sep 24, 2011 3:29 pm

Seems as lip damage is a common occurrance so as Im repairing an Ultrex lip at the moment, I'll show what I do to fix it.

This lip has a few large cracks through it and has snapped the centre bracket off.

Materials needed:

Sandpaper 80 - 400 grit.
Fibreglass kit
Body filler kit
Dremel
Matt / Satin black paint

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Start by roughing up the area that is going to be fibreglassed with 80 grit sandpaper. A rough surface will help the resin hold even more.
Clean the area free of dust with some mineral turps / Prepsol, etc.
Cut the fibreglass matting to shape to cover the damaged area with approx 150mm past the edges of the damaged area. any excess outside the lip is easily trimmed later.
Position the lip in a way so that the cracks are aligned.

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Mix the resin as per the instructions and brush on a layer of resin to the area to be repaired.
Lay the fibreglass matting over this and then apply more resin to the top of the matting with a brush spreading it out until the matting has gone transparent.

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I let this cure for 24 hours before turning the lip over and repeating this process on the bottom crack.

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Once this cured, trimmed the excess matting off to the lip edge.
Use a Dremel to V the cracks to allow a better area for the body filler to adhere and sanded the area.
Mix the body filler as per the instructions and overfill the Dremeled channel.

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Re: DIY - Repair STi / Ultrex lip

Postby cruisn » Sat Sep 24, 2011 3:31 pm

Sanded back the body filler and then gave the area a few coats of primer filler.

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I made up a proper alloy centre bracket, measured off a genuine STi lip....

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Last edited by cruisn on Sat Oct 01, 2011 3:04 pm, edited 2 times in total.
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Re: DIY - Repair STi / Ultrex lip

Postby eckymosis » Sat Sep 24, 2011 5:03 pm

It's coming along great Mark!

Can't wait to see the end result :)
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Re: DIY - Repair STi / Ultrex lip

Postby cruisn » Sat Oct 01, 2011 3:04 pm

Second post updated.....
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Re: DIY - Repair STi / Ultrex lip

Postby cruisn » Wed Oct 05, 2011 8:43 am

All finished.

A coat of paint and an Ebay STi badge and no ones the wiser. ;)

Repaired areas...

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Finished...

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Re: DIY - Repair STi / Ultrex lip

Postby 3rspecb » Wed Oct 05, 2011 11:04 am

awesome, great work..
MY06 3rspecb manual sedan, Urban Grey- Shockworks Coilovers '- Gone

MY17 SSv Redline, manual sedan, White.
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Re: DIY - Repair STi / Ultrex lip

Postby hamish_023 » Wed Oct 05, 2011 11:58 am

How does the paint flex with the lip? Waterbased?
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Re: DIY - Repair STi / Ultrex lip

Postby cruisn » Wed Oct 05, 2011 6:46 pm

Mineral based paint. I can grab the lip and twist it.

The lip will break before the paint cracks. :wink:
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Re: DIY - Repair STi / Ultrex lip

Postby hamish_023 » Wed Oct 05, 2011 7:35 pm

cruisn wrote:Mineral based paint. I can grab the lip and twist it.

The lip will break before the paint cracks. :wink:


Mineral based paint? :?
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Re: DIY - Repair STi / Ultrex lip

Postby cruisn » Wed Oct 05, 2011 8:15 pm

hamish_023 wrote:Mineral based paint? :?


Sorry oil based. :P
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Re: DIY - Repair STi / Ultrex lip

Postby eckymosis » Fri Oct 07, 2011 10:22 am

Looks fantastic Mark.

Good as, if not better than, new ;)
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Re: DIY - Repair STi / Ultrex lip

Postby cruisn » Sun Oct 09, 2011 7:56 am

No worries Eddy. :D
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Re: DIY - Repair STi / Ultrex lip

Postby cliffo3rb » Thu Jun 07, 2012 5:48 pm

Just repaired my lip using this method after an altercation with a driveway.

Thanks Mark!
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Re: DIY - Repair STi / Ultrex lip

Postby dr20t » Fri Jun 08, 2012 5:16 pm

I bought a genuine STi lip that wasnt cracked but was scratched to buggery - i mean to buggery

went over the whole thing with 80 grit to remove all the course scratches (some were extremely deep)

then went over with 120 the whole thing, then 360, 600, 800 and 1200

Smooth as anything now - (shitty i-phone pics):

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ABOVE IS THE UNPOLISHED SIDE (ONLY SANDED WITH 1200)

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THIS SIDE HAS BEEN POLISHED - DONT KNOW IF YOU CAN TELL

shoe polished it on the driver's side only (dont know whether to paint it or continue polishing or maybe use another product to polish it) - any suggestions, mark?

Cheers

Mick
Addicted to corn juice....

My FrankenStien build thread here: viewtopic.php?t=14137
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