Bumper Repair - '90 Westy

[WestwardHo]

I’ve owned a very clean ’90 Westy for 3 years. I want to do some bumper repairs.

There are 3 cracks showing on the underside that go inward maybe 1½”, a deep scrape (about the size of a silver dollar) on an outer corner, and a 13” horizontal split running across the center of the bumper about 3/8” above the bottom edge. I’m surprised this section has not broken away by now.
I plan to use West Marine Epoxy and Hardener (slow), and apply fiberglass cloth following the dry method.
I have cleaned up areas to be worked with a Dremel and sanding drum.

Questions.
Is sanding of the inside of the bumper surface needed? It seems like its roughness will provide sufficient bonding for the epoxy.

Is it recommended I run fiberglass cloth along the inside to cover all cracks, or is epoxy by itself sufficient?

For the 13” split along the bottom, is it best to wrap fiberglass cloth around the edge to cover both sides of the split, or is applying epoxy in and along the split on both sides sufficient?

If cloth is recommended, do I need to consider more than one layer?

To repair the scrape, I’m planning to use epoxy, and possibly fairing compound if I can’t get an acceptable finish with the epoxy alone. Any recommendations on this?

I plan to repaint the bumper when I’m finished with the repairs.

Finally, how important are the 2 rectangle rubber bumper supports that rest below and above the bumper bracket? I’m missing both from one side. Also wondering where to source these or what to use to make them.

I would love feedback from you who have experience repairing your bumpers. Please share any recommendations you have that I may not be thinking about; like questions I should be asking.

Sorry for the long post. I want to make sure I do this right.

Mike
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90 Westy; 2.1 waterboxer; 4 spd; 125K miles, cold a/c

[jlrftype7]

Our Mod covered this on his Late Model Vanagon Thread if I remember correctly.
https://www.thesamba.com/vw/forum/viewtopic.php?p=10120739#10120739
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'68 Westy- my first VW and vehicle/Bus- long gone.- sold it to a traveling Swiss couple....
'67 Type 3 Fastback, my 2nd car- gone
'69 Semi-Auto Stick Shift Beetle-gone
2017 MINI Coopers, our current DDs
‘84 Tin Top - Hilga....Auto

[do.dah]

Yeah, well, we'll go thru this again.
The "aero" bumpers are NOT bumpers. They are mostly a cosmetic thing.
Also, they are NOT fiberglass. They are some kinda thermoset plastic, that may have some fiberglass strands imbedded, but, I think what looks like glass strands, is just a crystalline form of the plastic.

Epoxy will bond pretty well to the inside of the bumper. There are pro/cons to matte glass vs cloth glass.
I used alternating layers of matte and cloth on all of my cladding, about a total of 12 layers for the bumpers, over the entire inside, being careful to make sure the mounting points are not greatly affected. Yes, that makes that area weaker, but what're gonna do?
On my rear bumper, I put a piece of steel bar stock in the depressed area the full lenght of the bumper. I did this mostly cuz my bumper was so badly fractured, and the bar stock helped stablize everything while I was piecing it all back together.

While the epoxy bonds pretty well, over time, and with the occasional bumps and scrapes of daily driving, the thermoset will separate from the glass, so having a full glass job on the inside, will make patching easier. I also think, as my rear bumper continues to shed bits and pieces, eventually I'll be left with a total glass bumper that I can gel coat over for a better look?

Also, be very aware, fiberglass is very flammable! But, we don't hafta worry about fire, no vanagon has ever gone up in flames....... The original cladding, being a thermoset, is quite fire resistant.

[djkeev]

Oh Duncan! When we need you the most, You've gone and left us....... 🥺
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[PDXWesty]

After having my Westy for years, I pulled the rear bumper off and found this. I had no idea it had ever been repaired. Looks like some copper had been riveted on the back and bondo used on the front. No way to tell and it had lasted many years. Fiberglass isn't necessary if the back is reinforced in some manner. The rivets must have been countersunk on the front to make it mostly flush.

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89 Westy 2.1 Auto

[jlrftype7]

[WestwardHo]

Looks like someone cared about the repair they were making. Hopefully the work I'm starting on my bumper will ultimately reflect the same.
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90 Westy; 2.1 waterboxer; 4 spd; 125K miles, cold a/c

[WestwardHo]

do.dah: Thanks for the feedback. My PO had welded a 21 lb steel bar across the backside of the bumper using steel straps welded to the toe hooks. I did glass repairs on boats in the past but never bumpers. I have a little to learn on this one.
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90 Westy; 2.1 waterboxer; 4 spd; 125K miles, cold a/c

[jlrftype7]

[WestwardHo]

Is Duncan no longer with us?
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90 Westy; 2.1 waterboxer; 4 spd; 125K miles, cold a/c

[RoryGirl]