Thursday, August 5, 2021

2009 Honda Fit -- Front Bumper Repair...


The small panel between the bumper cover and the upper radiator support needs to be removed first.  Just a bunch of plastic push-clips...

There's one screw at the end of the bumper cover to fender interface.

Phillips head screw...

Three holes that clip into tabs on the black plastic part, just below the fender...

Four holes (rectangular) that clip into tabs under the headlamp.

Need to disconnect the fog lamps...


Got the bumper cover off.
Due to the under tray missing under the engine compartment, and the fender inner liners being damaged at the bottoms, nothing had to be removed at the bottom of the bumper cover...

The screw holes on the two ends of the bumper cover are torn out.
Will fix with bumper repair epoxy.

Passenger side...

Passenger side, the area below the headlamp...

All of the rectangular holes in the bumper cover are intact (not torn out).
The two holes for plastic clips on the inner side of the headlamps are torn out...
This is the passenger side.


This is the driver's side hole that's also torn out...

Driver's side of the bumper cover, below the headlamp...

Driver's side end of the bumper cover.

Driver's side screw hole at the end of the cover is torn out...


There's two rectangular holes that clip into tabs on the bumper beam area...


Driver's side bumper cover receiving tabs are all broken (all 4)...

The bumper cover interface tabs at the end of the driver's side are part of this black plastic part.
It's held in place with one screw and plastic tabs on the RH end.
On the driver's side, the plastic tabs are broken off...

The driver's side fender inner liner is damaged and a large portion is missing...

This one rocker cover trim screw is not fully installed...

passenger side bumper cover tabs under the headlamp are all intact & OK...




The passenger side interface tabs at the fender are also in good condition and the locking tabs (arrow) are also OK (unlike the driver's side...).

Plastic tabs in place & OK.

Passenger side finder inner liner is also damaged at the bottom where it interfaces with the bumper cover...

Fog lamp bulbs look OK (filament is not broken).

Driver's side fog lamp assembly is broken (so is the plastic lens on the front side).




Bottom of the bumper cover where the small air-dam is clipped to the cover.


Need to replace this piece...


This is where the repaired hole on the bumper cover interfaces ...



Sanded down the broken area of the bumper cover to taper it down to give space and interface for the epoxy...







After the sanding, before the epoxy, sprayed on some adhesion promoter.
It needs to dry/flash-off.  You have about 15 minutes to apply the epoxy...

Bumper cover epoxy (when fully cured, stays somewhat plyable).

Apply the epoxy between a plastic reinforcing material & let it set...




Mixed a batch per hole.
This epoxy hardens pretty quickly.
It's supposed to be 5 minute work time but with the heat and humidity today, actual work time is 2 to 3 minutes...
Found out the hard way by mixing up enough material to do all 4 holes at once.  But, it set so quickly, couldn't even do one hole!

So, have to work quickly and do one hole at a time.

The fender flange with the hole with for the screw is deformed (probably from when the bumper cover was torn off).
Will persuade it back more flush using a punch...

After adjusting...


Same issue on the driver's side...

After adjusting...

Starret punch set...

Driver's side (broken off tabs)...

Used a sharp blade to trim the epoxy to the desired shape and thickness...

Drilled the hole...









Lunch break...

The screws at the end of the bumper cover should go into a plastic "nut" on the fender.
The plastic is missing so used a larger screw, temporarily.  Will order replacement plastic nuts...


Engine bay under cover(s) missing...


Passenger side fender inner liner.
One clip missing at the lower frame rail...

Putting the bumper cover back on.
the black plastic trim panel "grabs" the front edge of the bumper and is held in place with many plastic clips.



Cover back in place...

The clip on the left is the correct size/one for the Honda Fit.
The one on the right is from something else and is slightly too small but will just about work...


Broken driver's side fog light lens.
Will check to see how much a replacement cost...


 

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