So I ripped my front bumper cover off today... how would you fix this?

[Jargon]

I guess the curb was too high . Backed out and the sides of the bumper cover ripped off. Other than this part shown here, it is actually fine and could be reinstalled without issue.

How would you fix this?

[bwdysart]

https://nickscarblog.com/diy/b7-audi...pair-alignment

Check this out, great write up


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[jonathandugan20]

I used jb plastiweld and mesh dry wall tape... I tried the putty and just the plasticweld but the mesh plastiweld layered combo was best....... could have bought a new bumper for less then I spent on products

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[Jeevan]

if you dont wanna go thru hassle of removing and realignment of the bumper after plastic weld, Just visit a junk yard and find a nice looking bumper for 150$

[Older_not_Wiser]

The bumpers on the B7 are polypropylene which does not take well to bonding. I picked up a project car Avant last fall with the same issue on both sides. I found some bonding material that is specifically made for PP and that worked well. You will have to carefully remove the paint from the inside corners and the torn edge using sandpaper and then mask off the outside painted part with some painters tape and figure out a way to clamp it together while the bonding cures. It also took a little bit of careful clean up after words to get the painters tape off and to carefully sand the bonding right at the seam so the bumper fits well again. If you are careful and patient it is do-able.

The bonding has an etchant in it that allows it to adhere to PP. I bought 2 of the small bi-packs linked below and I only used one to bond both sides.

https://www.chemical-concepts.com/pe...-adhesive.html

[Okedokey]

The bumpers on the B7 are polypropylene which does not take well to bonding. I picked up a project car Avant last fall with the same issue on both sides. I found some bonding material that is specifically made for PP and that worked well. You will have to carefully remove the paint from the inside corners and the torn edge using sandpaper and then mask off the outside painted part with some painters tape and figure out a way to clamp it together while the bonding cures. It also took a little bit of careful clean up after words to get the painters tape off and to carefully sand the bonding right at the seam so the bumper fits well again. If you are careful and patient it is do-able.

The bonding has an etchant in it that allows it to adhere to PP. I bought 2 of the small bi-packs linked below and I only used one to bond both sides.

https://www.chemical-concepts.com/pe...-adhesive.html

PP or ABS?

[Older_not_Wiser]

A4 base line; w/o headlamp washer
Audi (2006-2008) Front PP (Polypropylene)

A4 w/S-Line Pkg; w/Headlamp Washers
Audi (2005-2008) Front PP (Polypropylene)

A4 Sedan/Wagon; w/o Sport Pkg; w/o Headlamp Washer
Audi (2005-2008) Front PP (Polypropylene)

A4 Cabrio
Audi (2003-2004) Front PP (Polypropylene)

A4 Sedan/Wagon; From 3-03; w/o Parking Aid
Audi (2003-2005) Front PP (Polypropylene)

A4 Sedan/Wagon; To 3/03
Audi (2002-2003) Front PP (Polypropylene)

A4 Sedan; w/o S-Line Pkg; w/o Parking Aid
Audi (2009-2012) Rear PP (Polypropylene)

A4 4dr wagon; w/o parking aid
Audi (2005-2008) Rear PP (Polypropylene)

A4 4dr sedan; w/o parking aid
Audi (2005-2008) Rear PP (Polypropylene)

A4 Sedan; w/o Parking Aid
Audi (2004-2005) Rear PP (Polypropylene)

A4 Cabrio; w/o park sensor
Audi (2003-2006) Rear PP (Polypropylene)

A4 4dr wagon; w/1.8L engine; w/o park sensor
Audi (2002-2005) Rear PP (Polypropylene)

A4 Sedan; w/o Parking Aid
Audi (2002-2003) Rear PP (Polypropylene)

https://www.polyvance.com/bumperid.php

[rhfosu]

I'd invest in some fusor products. They bond well with PP. I have used them for repair in the past.

[Ray1031]

Been there done that, new bumper from fleabay


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[Mister J]

I experienced the exact same thing. On a nice day thinking about washing my car, stopped at a gas station to buy a drink and ripped the bumper off from a parking block the same way. I ended up just finding a used bumper that was the same color.

Sorry, not helpful but I feel your pain. I wish I had seen the above repair write up before.

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[Jeevan]

I experienced the exact same thing. On a nice day thinking about washing my car, stopped at a gas station to buy a drink and ripped the bumper off from a parking block the same way. I ended up just finding a used bumper that was the same color.

Sorry, not helpful but I feel your pain. I wish I had seen the above repair write up before.

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perks of removing lower belly pan. I am still happy that its not there because engine cools properly without any air blocks


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[rhfosu]

Fusor 153 with the mesh. Use the 602EZ surface modifier first. It will be good as new.

[dalmation53]

phil has a diy on this im the tech section. fusor will help.

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[FatMongo]

Subscribing for the links.

[Jargon]

Thanks everyone for the opinions and advice. Happy (sad) to see I'm not the only one this has happened to :)

Three options I've been pricing out last two days, priced from low to high:

1. Repair it.
2. Find replacement bumper from junkyard/ebay/CL and throw it on.
3. Buy a new bumper.

I'm going to try option 1. I ordered the fusor which should arrive in a week or so; could not find any locally.

Didn't find any matching bumpers at local junkyards or craigslist.

As far as option 3 goes... Local body/paint shops are quoting me anywhere from $350 - $450 JUST TO PAINT A NEW BUMPER if I brought them a new one, primed and uninstalled. I found a fella locally who sells new Audi bumpers primed for $90, or painted for $270. That's probably the route I'll go if I can't repair it.

I'll provide an update with my success/failure.

[dalmation53]

dude you are complicating yourself. i had this happen to me 7 years ago. i had no mechanical experience and fuzor fixed it. take your time don't rush it. you will be fine you ca do this..

Thanks everyone for the opinions and advice. Happy (sad) to see I'm not the only one this has happened to :)

Three options I've been pricing out last two days, priced from low to high:

1. Repair it.
2. Find replacement bumper from junkyard/ebay/CL and throw it on.
3. Buy a new bumper.

I'm going to try option 1. I ordered the fusor which should arrive in a week or so; could not find any locally.

Didn't find any matching bumpers at local junkyards or craigslist.

As far as option 3 goes... Local body/paint shops are quoting me anywhere from $350 - $450 JUST TO PAINT A NEW BUMPER if I brought them a new one, primed and uninstalled. I found a fella locally who sells new Audi bumpers primed for $90, or painted for $270. That's probably the route I'll go if I can't repair it.

I'll provide an update with my success/failure.

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[Okedokey]

Thanks everyone for the opinions and advice. Happy (sad) to see I'm not the only one this has happened to :)

Three options I've been pricing out last two days, priced from low to high:

1. Repair it.
2. Find replacement bumper from junkyard/ebay/CL and throw it on.
3. Buy a new bumper.

I'm going to try option 1. I ordered the fusor which should arrive in a week or so; could not find any locally.

Didn't find any matching bumpers at local junkyards or craigslist.

As far as option 3 goes... Local body/paint shops are quoting me anywhere from $350 - $450 JUST TO PAINT A NEW BUMPER if I brought them a new one, primed and uninstalled. I found a fella locally who sells new Audi bumpers primed for $90, or painted for $270. That's probably the route I'll go if I can't repair it.

I'll provide an update with my success/failure.

Nice thinking. I would just make sure you prepare the surface adequately. Can you also take a pic of the polymer code details as I know its been listed as PP, but geez, I could've sworn mine was ABS.

[rhfosu]

Nice thinking. I would just make sure you prepare the surface adequately. Can you also take a pic of the polymer code details as I know its been listed as PP, but geez, I could've sworn mine was ABS.

OE bumpers are PP. Surface prep is absolutely critical, esp with fusor 153. OP MUST also buy and use the surface modifier before attempting repair.

[Charles.waite]

perks of removing lower belly pan. I am still happy that its not there because engine cools properly without any air blocks


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I don't run a belly pan (out of laziness), but the belly pan is designed to increase airflow and cooling in the engine bay and smooth out the undercar aero. So if you have one you're best served installing it.

Which reminds me next time I change the oil, I really should install mine. That would also require me to properly attach the front bumper and to do that I'd need to finish sorting out my city light LED resistor wiring. Two small kids and two working parents (and no garage or driveway) make working on my car the last priority sadly...

[Okedokey]

I don't run a belly pan (out of laziness), but the belly pan is designed to increase airflow and cooling in the engine bay and smooth out the undercar aero. So if you have one you're best served installing it.

My understanding is in Australia theyre removed as they provide insufficient cooling?? Im all sorts of wrong in this thread

[Jeevan]

My understanding is in Australia theyre removed as they provide insufficient cooling?? Im all sorts of wrong in this thread

Belly Pan's purpose is to reduce drag and Lift on the car during high speeds so that MPG will improve. In snow belts, it will help with rust prevention. They dont do shit when it comes to cooling. Many countries closer to equator never run belly pans for this reason. As per Physics laws that I know, More surface area is directly proportional to more air flow, cooling.

[Charles.waite]

Lol okay...

[Jeevan]

Belly Pan's purpose is to reduce drag and Lift on the car during high speeds so that MPG will improve. In snow belts, it will help with rust prevention. They dont do shit when it comes to cooling. Many countries closer to equator never run belly pans for this reason. As per Physics laws that I know, More surface area is directly proportional to more air flow, cooling. Please correct me if I am wrong here

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[Charles.waite]

Our cars aren’t air cooled VWs. The surface area for cooling is the radiator. The undertray being there or not doesn’t affect cooling surface area.

Okeydokey, most used cars are missing their trays, not sure if Audi specced them without trays there but I strongly doubt they did because the way the ducting is designed, they promote air flow through the radiator and engine bay to help pull the cold air from outside through the rad and out underneath the car. I also helps aerodynamics yes.

Jeevan - Our cars don’t have any cooling issues whatsoever (that aren’t caused by old/failed components) so removing because you think it provides better cooling is sorta pointless. Audi has used pretty much the same cooling layout from the b5s on. It works and works well as I’ve yet to hear of any widespread cooling issues anywhere in the world on these platforms. You can say “it’s physics” and you’re right there, but you application for physics in this case is completely off base. The belly pan has ZERO effect on the cooling surface area. Unless you’re thinking that radiant cooling plays a meaningful role in cooling, it doesn’t. And even if it did, the belly pan increases airflow out of the engine bay so it theoretically would even help radiant cooling.

[Okedokey]

yep, researched it, provides negative pressure to aid preference of air over radiator. mainly for noise though

[Jargon]

Well I went ahead and used the fusor 620EZ and 143 to try to fix it. I can see that this is the best - and a pretty simple - option. However, I f***ed up the first attempt and I wanted to share my mistakes so others don't make the same mistake.

I didn't do enough research ahead of time to learn to that the mixing nozzles for the fusor 143 are not reusable and that the fusor hardens within minutes once mixed to the point where the nozzle cannot be used again. The fusor I ordered came with two nozzles, like nickscarblog said, and I had used the first nozzle to "test" the flow of the fusor. By the time I went to apply it to the bumper (which was like two minutes after), it had already hardened so I had to use the second nozzle.

I managed to get the inside of the bumper attached/adhered but I don't think it is strong enough without the rest of it also adhered, which I'll need another nozzle for since the second nozzle hardened before I had time to apply the rest. I actually didn't realize the mix was coming out the back of the tube when I was squeezing it after the tip had hardened.



It seems to have done a good job where I was able to apply the fusor though; good enough that I could take it off the car and the broken piece remained attached.



The fusor does not mix well without these nozzles, so I'm waiting a couple more days for another kit to arrive to finish.

[dalmation53]

noice.. well done.

Well I went ahead and used the fusor 620EZ and 143 to try to fix it. I can see that this is the best - and a pretty simple - option. However, I f***ed up the first attempt and I wanted to share my mistakes so others don't make the same mistake.

I didn't do enough research ahead of time to learn to that the mixing nozzles for the fusor 143 are not reusable and that the fusor hardens within minutes once mixed to the point where the nozzle cannot be used again. The fusor I ordered came with two nozzles, like nickscarblog said, and I had used the first nozzle to "test" the flow of the fusor. By the time I went to apply it to the bumper (which was like two minutes after), it had already hardened so I had to use the second nozzle.

I managed to get the inside of the bumper attached/adhered but I don't think it is strong enough without the rest of it also adhered, which I'll need another nozzle for since the second nozzle hardened before I had time to apply the rest. I actually didn't realize the mix was coming out the back of the tube when I was squeezing it after the tip had hardened.



It seems to have done a good job where I was able to apply the fusor though; good enough that I could take it off the car and the broken piece remained attached.



The fusor does not mix well without these nozzles, so I'm waiting a couple more days for another kit to arrive to finish.

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[Acomat05]

Well I went ahead and used the fusor 620EZ and 143 to try to fix it. I can see that this is the best - and a pretty simple - option. However, I f***ed up the first attempt and I wanted to share my mistakes so others don't make the same mistake.

I didn't do enough research ahead of time to learn to that the mixing nozzles for the fusor 143 are not reusable and that the fusor hardens within minutes once mixed to the point where the nozzle cannot be used again. The fusor I ordered came with two nozzles, like nickscarblog said, and I had used the first nozzle to "test" the flow of the fusor. By the time I went to apply it to the bumper (which was like two minutes after), it had already hardened so I had to use the second nozzle.

I managed to get the inside of the bumper attached/adhered but I don't think it is strong enough without the rest of it also adhered, which I'll need another nozzle for since the second nozzle hardened before I had time to apply the rest. I actually didn't realize the mix was coming out the back of the tube when I was squeezing it after the tip had hardened.



It seems to have done a good job where I was able to apply the fusor though; good enough that I could take it off the car and the broken piece remained attached.



The fusor does not mix well without these nozzles, so I'm waiting a couple more days for another kit to arrive to finish.

Glad you are able to fix it man, my wife just ripped mine off and broke both sides at Wally World and I just put that bumper and new grill and she damaged the grill too. Out of luck just found a guy 2 hours away who had an original S4 bumper and grill and many other parts he was trying to sell/give away as he was moving. Now lke some of the folks chimed in new to find a descent body shop to paint it as it was not birlliant black. After 5 hours of traveling it is time for to put the car together until the body shop can do my bumper...

[rhfosu]

Yeah, there is a learning curve. You have to buy their special gun, and you need to buy a bag of nozzles. I also let a nozzle harden up on me once once and wasted half the fusor blowing it out the back. Made quite the mess. Use the reinforcing mesh if you can. It really helps a lot with strength.

[Older_not_Wiser]

You don't need the mixing nozzle. I just squeeze out equal parts onto a piece of cardboard and mix and apply with a popsicle stick. Just like you would with JB Weld.

And, yes, you have to work quickly. I found this way easier to make many small batches and do a section at a time without using a ton of material. Once it is tacked on in the proper position, it was much easier to then go in and re-enforce with a larger amount of material.

[B72011]

I have to do this to my bumper to get my car ready for sale. Two Qs.
1. Is drywall tape on to use as a mesh w the fusor chemicals? Has anyone used it? If you have used fusor w mesh .....what type did you use?
2. The upper portion of the plastic on the front that sits on the very top of the bumper cover. There are some stickers on jt...oil info.....does fusor work on this seemingly different types of plastic? THx

[Jargon]

Well I am pretty happy with the results. It isn't perfect but for $40 of fusor it is definitely worth it.



It isn't lined up perfectly under the headlight, but I can't really do much about it and it's good enough for me.





Nothing to fret about. It's strong and isn't going anywhere.

Thank you everyone for the help.

[bwdysart]

Well I am pretty happy with the results. It isn't perfect but for $40 of fusor it is definitely worth it.



It isn't lined up perfectly under the headlight, but I can't really do much about it and it's good enough for me.





Nothing to fret about. It's strong and isn't going anywhere.

Thank you everyone for the help.

Mine doesn’t line up right either, my fmic pushes on the bumper somewhere and I don’t know where. You’ll forget about it real quick, great work on the repair


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