Subject: Plastic Bumper Conversion for E30 with metal diving board bumpers Lots of PICS!) Author: hgjacobsen as IBHenry® : member since May, 2007 : 7075 posts Posted on: 2009-03-24 19:48:23

I've been wanting to do this for some time. I've been trying to find a good write up with some good pictures. Well I went and did it myself. Hope this helps anyone that is interested in doing this mod.
Here is what you will need.
Plastic Exterior bumper cover WITH fender attachments (possibly turn signals, if yours is the fat signals, you will need the newer thin ones,you can reuse your side turn signal if they are the long thin ones, if its like an 84-86,87(?), you might want to snag the side turn signals).
Internal bumper with front turn signals, "clip the turn signal harness to tap into later"
Both bumper shocks and mounting bolts "and" the long vertical bolts that hold the bumper
The front valance with bolts (extra never hurt)
Lower Valance lip (which I still need)
The lower engine shield (which I still need)
Fog lights, "clip the wire harness to tap into later"
You can reuse your side turn signal if they are the long this ones, if its like an 84-86,87(?), you might want to snag the side turn signals

Tools
8mm wrench and sockets
10mm wrench and sockets
13mm socket
Ratchet and extensions
3/8 Allen or metric equivalent
philips screwdriver
a package of wire taps (Radioshack has the most at the least price)
and what ever else you may need


Before


New front valance primered and painted, bumper painted too (forgot pic)


Unbolt bumper with allen wrench, 2 bolts underneath and unplug turn signals and fog lights



Unbolt plastic covers, covered the metal bumper (may not apply to older e30s), tow 10mm bolts from under and behind fender


Unbolt valance from fender, 1 bolt on top and one on bottom



Remove 2 bolts just to the inside of the high beams 10mm (?)



2 more 8mm bolts under the tow hooks



Use some needle nose pliers to squeeze the clips and push through to the backside of the bumper


You will need to pull the fender outwards a bit to remove the old valance, as the valance is just a bit behind the fender.


I suggest removing the lower engine shield at this point.
Remove lower valance lip, 10mm bolt on each fender and front screws
Remove the outer grill pieces 2 Philips screws each and 3 clips, kidney held in by 2 clips.

Remove old bumper shocks 2 bolts each 13mm



Before installing new bumper shocks, you may need to modify the internal shock holder (for lack of a better term), using a screwdriver and a sledge to create more room. The new ones are a bit fatter.




Install bumper shocks, check to be sure you have them in correctly, I installed them 180 out the first time. Trial fit the plastic bumper to check bumper shock before torquing them down.


Before bolting on the new front valance, you will need to cut off both tow hooks. I used a grinder (was too big) and a Dremel. I cut half way and used the sledge to persuade them off. ALSO! The horn on the driver side will be in the way, it is on a bracket that can be bent out of the way by hand (no pic).


You should be at this point

The inner fenders are not the right fitment and may need to be modified or changed, I forced my new valance to fit. =^)

Bolt on the fender attachment pieces "loosely", they can only go on one way


Before bolting on the inner bumper, you will need to convert the turn signal plug to the newer bumper. Old style (no pic) is flat, new style is round


Take the harness you clipped off and use a wire tap to attach it to the original harness (I left my original in place, versus snipping it off). Don't forget to do the same to the fog lights.


Now bolt on the inner bumper, making sure you use the long bolts (yes I mixed them up!)


Slide on the new plastic bumper (((be sure to guide the side turn signal harness out through the side turn signal opening))),
you will need to guide it onto the fender attachments,
"Pop" the plastic bumper onto the inner bumper (there are clips that go all around the lower front)once in place you can now tighten the fender attachments from behind the fender. Pop in your turn signals and your done!


I painted the kidneys for fun.


I still need the lower valance lip and the lower engine cover. If I forgot something, oh well. You are on your own!!! Have fun modding!
Best of Luck
Henry

"No matter where you go, there you are."
2001 BMW 740iL

Mods: New cluster from BMWNA!, Quad taillights, Cross drilled rotors and ceramic pads all the way around, new Traction struts & Control arms=No shimmy! Angel Eyes, done! I'm in the Valley Pan club!

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