Genuine Body Kit: Self-Fitting Diary

Following the 'trial fit/opinions' thread last week, I've decided to take the plunge and paint and fit the kit.... myself.

To aid other members, and to act as a guide for others considering the kit I've decided to document my self-fitting process.

Please keep all opinions and general discussion in the other thread, but feel free to comment on the actual fitting process in here!

Introduction:
I purchased the kit in October 2006 after seeing Dubbsy's A2 a few times in the flesh. It was bought following an advertisement placed on these forums for £150 (£100 less than advertised :p ) but I had to chuck in some beer ;)

Luckily for me, the kit came with TWO rear valances, so, obviously the second one found its way onto eBay, and after a colossal bit of packing and a rather large postage charge it made its way to London by courier to meet its new owner, leaving me £75 better off. Thus my kit has to date cost me £75 - not bad eh? :p

I have both the side skirts, front and rear valences and all of the factory supplied fittings and fixings (although I suspect the bonding agents will now be next to useless given the kit was manufactured in July 2002); except the rear towing eye cover (often missing from kits it seems).

Following the trial fit, I set about researching self spraying. I have previously colour coded items such as mirror housings and rear valances, but never an entire kit. From my findings, I don't think it's going to take a great leap in knowledge to pull this off, however, it will obviously take a fair bit of time and effort - but could save me in the region of £400-£600.

The Plan:
It obviously helps given the fact that the kit comes ready-primed, however, I will still need to prep and prime the lower door 'sills' and also manufacture a suitable towing-eye cover. To get the required paint mixed up there is obviously HellFrauds who charge £9.99 for a 300ml can of which 100ml is propellant. However, they will also make up a 1 litre 'tub' for £25.. obviously the better option. I'm open to other suggestions as to where to get the paint, but I am quite fortunate to have 3 HellFrauds close by, one of which has quite a knowledgeable paint guy who I have dealt with before. I can hire a spray gun for a weekend for circa £40 and have a garage that I can work in.

So, for the record here's how I plan to proceed:
1) Manufacture a suitable towing eye cover
2) Prep and prime the towing eye cover and door sills
3) Lightly key all components with wet and dry to remove any priming imperfections
4) Get paint mixed up and hire gun
5) Spray with multiple light coats and leave to cure for a week or so
6) Apply clear-coat (from past experience, this is the bit I'm not looking forward to!). Then leave for a week or so
7) Lightly use rubbing compound to remove any clear coat imperfections
8) Using swirl remover or similar, polish up the finished items
9) Select suitable bonding agent (suggestions?)
10) Fit using as many pairs of hands for assistance as possible :p
 
Recap: Trial Fit Pics

Just for completeness, here's how my A2 looked when I test fitted the kit last weekend:

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DSCF1310.jpg


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Stay tuned as tomorrow, I begin.
..Well, I have already started, but more on that tomorrow when I have pics :p

Ian
 
Is it possible to get the kit sprayed at a garage and then fit it yourself? Most charges for repairs/spraying is for the prepping.Might not cost you much more to get a local bodyshop to paint it by the time youve paid for gun/compressor hire etc.Once went to Audi to repair scrathes on wheel arch of an a4 from a parking hit and run incident.They quoted £560.00!! got it 'blown in' at a bodyshop for £80.00
 
Great link Spike, many thanks.

Daz: I can see where you're coming from, however, the prices I quoted were in reference to me going to a bodyshop owned by a family friend and paying cash.. yup, granted the price would come down if I then fitted it afterwards but it's still going to cost in the region of £300 compared to the £100 or so it will cost me to self spray and fit.

This is a decision that I've deliberated much over, as I wasn't originally certain I would fit the kit let alone do it myself. Having seen 'less than perfect' professional jobs in the past by several bodyshops (both re fitting and colour matching), I can equal or better that myself for much less - plus I enjoy a practical challenge :D
 
hi ian if you order part no 8z0 898 405/3fz and see what you get but it will help you

cheers

robin
 
DAY 1.5: Towing Eye Cover Fabrication

DAY 1.5: Towing Eye Cover Fabrication

I decided to make this my first task given that I wouldn't be able to proceed with the actual spraying until I had resolved this issue, so I may as well get it out of the way!

After hunting around in the garage for a while, I stumbled across an old can of Car Plan Paris Blue spray paint (for my MK3 Escort), of which, the cap seemed a perfect fit diameter wise for the towing eye hole in the rear valance.

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So, off to work I went with a Stanley knife:

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After half an hour of filling/sanding and cutting things were taking shape:

100_2895.jpg
 
Next up was the problem of how to hold the cap in place. Given the valance has two slots for the standard plastic retainers, I decided to make use of these and create a 'spring fit' type clip in order to hold the cover in place. What better to use other than a humble paperclip..! I cut two slots in the 'centre cap' on the rear of my to-be cover and pushed through it the slightly straightened paperclip. Then bending the ends of the paperclip through 90 degrees produced:

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As I had to do a fair bit of specific shaping to the front side of my cover to match the curvature of the valance, I decided to leave the plastic 'leg' on the underside of the cap so as to assure that the cover only fitted the one way around. Whilst in place (above) I filled and set the paperclip in place using hot melt glue in order to preserve the positioning that I had attained. I chose the hot melt glue as it would set hard, but offer a degree of flexibility - required when fitting and removing the cover.

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Finally I used 400 grit wet and dry to smooth the cap, before applying several coats of primer (I'll add another coat when I get some grey primer next week in order to prime the side strips/sills from the doors), and thus all undercoats will be grey before spraying with the silver paint.

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Brilliant!

Prime example of good old British ingenuity, not quite up to fixing a head gasket using chewing gum and a cigarette paper, but not far off!

Cheers,

Mike
 
robin said:
you have just made one

robin
HAHA.. oh dear :rolleyes: This was more fun than a trip to a dealer.. :eek:

Do I presume you are also now an owner of a full body kit?


Skipton01 said:
Brilliant!

Prime example of good old British ingenuity, not quite up to fixing a head gasket using chewing gum and a cigarette paper, but not far off!

Cheers,

Mike
Cheers Mike, if only I'd documented my methods for door card creak reduction yesterday I may have been able to equal that benchmark level in your eyes!
 
Do I presume you are also now an owner of a full body kit?

you do presume right
when i got it back home there was a little pack which was in with the glue tow eye cover thats why i asked about the glue in case yours was in with the glue to
but my glue is out of date but will try some to see if it will work

cheers
robin
 
driveforward said:
;)

They simply unscrew, so I will paint them along with the rest of the kit

Please let me know if the black trim has adhesive on them since I'm thinking of doing something about the gap between the door and the trim.
This gap is a perfect place for grit, salt and dirt to collect. I'm thinking of sealing this place with silicone or similar. Interesting thread btw, keep up the good work.
 
Xiter said:
Please let me know if the black trim has adhesive on them since I'm thinking of doing something about the gap between the door and the trim.
This gap is a perfect place for grit, salt and dirt to collect. I'm thinking of sealing this place with silicone or similar. Interesting thread btw, keep up the good work.
No problem, will include the removal process in the diary :)

Robin: I think I checked in the 'glue boxes' for the plastic cover a while back.. what's the betting that if I look again I'll find a towing eye cover :p
 
DON'T LOOK!!!!
not after all the hard work you have put in
do you have the fitting manual with your kit as toby is going to post it to me as he has left it at work if not you can have a copy of it when i get it if you want

do you have all the black plastic bits for the end of the kit

cheers

robin
 
robin said:
DON'T LOOK!!!!
not after all the hard work you have put in
do you have the fitting manual with your kit as toby is going to post it to me as he has left it at work if not you can have a copy of it when i get it if you want

do you have all the black plastic bits for the end of the kit

cheers

robin
Hehe.. I probably shouldn't!
I have the manual for the front and rear, but not the side skirts - if you get that it would be good to see! I have the black spacers for the side skirts and the wind deflector bits for the rear... I think that's the lot :)
 
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