http://s985.photobucket.com/user/Nibli/library/Volvo?sort=6&page=1

Here is part one lets say. First of all, I went into this with only info gleaned from posts on web that it can be done. Each pic so far has its own write up. We ran out of time on Friday to even get the rear bumper permanently mounted. But we made progress. This being Memorial weekend.

I have a health problem and fatigue easily so it is with my observations and hired helps labor we attacked this little monster.

I must let this little ditty slip out concerning the bumper we will try to use on the front; It will NOT fit at all due to the present curvature. Pics will show what I mean. I am brainstorming what procedures might be needed to remedy this.

Ordered from California Pacific for $414.00 total to Kansas. Prompt shipping and full order received. I ordered the 62-67 full euro bumper package with bumperettes.

Dakar09,
What source did you use for 544 bumpers?

http://www.jbugs.com/category/vw-bug-bumpers-1952-1967.html

and its named in my first post with prices.

http://www.ipdusa.com/blogs/26/randall-chapman-s-1962-volvo-pv-544

Here is Randall Chapmans Volvo seen in a rod magazine sometime back. He states his bumpers are Volkswagen that have been flattened. Not very good pics of it though.

http://www.streetrodengineering.com/Customer%20Vehicles/customervehiclespg2.htm

found better pics of said car and VW bumpers. They have been bobbed heavily.

I will try and post mine. 59 vw stainless rear bolted right up and hugs so clean he front I indeed had to split and with a lead sack and a hammer, beat a shape into some flat stainless all hidden by the front plate we are required to display here in texas. If some one will host I can get pics of the fitting.

I haven't yet. I'm still a ways off from having the any bodywork done, but when I do the front bumpers will need re-dipping at the least and replacment in the rear due to rot. There is a place in MA that does serious rust repair and then re-dips them, but the cost may be more than new bumpers.

I know it will hurt $$$-wise, but I'll still be using 444/544 bumpers if replacement is needed.

I would think that any reshaping would wrinkle the chrome on the outside. Do you have any custom or hotrod shops nearby ? Maybe you could pick their brains.

Greg

Will be my next step I guess. Can you see the pictures in each thread?

The first time they did not, this time they did.

Greg

Viewed from your Photobucket page. See they have "Made in Brazil" on the packaging. If they are anything like the Brazilian ones we get here in the UK they will be spotting through with rust after about 6 months if they see any sort of bad weather. Seem to be just chrome on steel with little or no nickel, let alone copper. They might have improved but I wouldn't bet on it. The VW forums will know.

http://www.groupharrington.com/en/part/151/volvo-pv-544-euro-version-bumpers.html
Even with the towel rails, still under $1k. They can be made to haggle if you're tenacious.

As yours is a custom, maybe powdercoating the originals body colour might have been a cheaper, maybe nicer,way to go?

I applaud your attempt at ingenuity here, but I'd have gone with the true PV bumpers myself. The PV is not a "round" car in the same way the Beetles are, so the varying gaps between the bumper and the body would bug me after a while. And while I'm never one to shy away from fabrication/modification to make something fit, the amount of work here for the end result may not be worth it.

That said, keep plugging away at it!

And I would have jumped at any opportunity to own a nice set of Volvo bumpers, except I simply cannot afford $1400.00 (ebay)

The rear bumper took about 5 hours to install. the front, well, so far Im stumped. Bracketry is no problem. This pic was taken before the bolts were tightened, so there is a slight bit of sag on the right.

There is a picture attached to each of my posts and I dont see them in every post. What is the deal?

Regardless of wrapping these are NOT show quality bumpers. I ordered triple plated, nevertheless I see sand scratches of about 120 grit throughout the length of each bumper with small flat spots where prep over ground to get rid of deeper nicks.

I would consider these as almost parade quality bumpers. Another thing is I think these babies are about the thinnest bumpers evar! Like cereal box cardboard thickness. they will not withstand even a 1 mile per hour hit. Brackets compared to Volvo brackets,... less than half thickness. But hey, they are new and shiny!

Example of a "splotch" or bad spot.

Trial fit shows another niggling problem. All bumperettes have threaded receivers and are exactly one half of bolt hole off center. Die grinder needed for bumper holes it seems.

We picked the more curved bumper for the rear. It looks better, it fits the curve of the body well and has just the right amount of wrap around. Still juggling height, but were close.

It turns out the bumper is upside down. Those bumperettes dont stand vertical unless we flip it. Now the bumper looks a little odd with meaty curve on the bottom. Oh well.

Another view. Note this is a custom. The spare tire well is gone so is the passenger side mounting holes. At this point I have decided NOT to go into detail with the brackets and how to mount them. I suspect there will be quite a bit of modification needed no matter what.

How we solved our particular prob;

cut the Volkswagen bracket at the Y, mounted the Y pieces permenantly to bumper laid the long part flat against the panel that replaced the tire well. Sandwiched it to beefier bracket inside the trunk, and butted flat bracket to vertical Y part to be welded with L brackets. Like I said they will not be doing any serviceable "bumping" due to paper thin materials.

The driver side brackets are yet to be analyzed, but will probably be easier due to having stock bumper bracket holes.

Another view. We ended up raising the bumper 3 to 4 more inches.

This is as far as we got. I like very much the rear treatment. Its going to look mahvelous. I dont know about that front. The bumper with the least curve and length looked to be a shoo in for the front, but it pinches in too tight and hits the front fenders, and seems to have too much curve even now for the proper profile.

I have a shrinker/stretcher I think would be meaty enough to take out some curve but it will ruin the chrome lip at top and bottom. Any suggestions? I even considered torching the middle 2 feet without turning it blue and leaning on it to take some temper out of the curve. Scary thought.

Note;

The brackets on the left are for the rear bumper.

Due to curvature, the closer I want the bumper to fit to the front, the more interference there is with the fenders.

It seems to always follow the old axiom; you get what you paid for.

i am now thinking of cutting the bumper in two, inserting the original Volvo center section with bolts, which will put a good amount of "straight" to the middle of said bumper.