Front Bumper Removal - the hard way?

[littleboyblues]

Im trying to get my front bumper off and well...its never been off. The thing is so rusted that i broke the torex bolt that holds it in.

Is there a way of getting the bumper off without taking that bolt off.

I have a late e30.

Thanks in advance

[DesktopDave]

I stripped one myself.  Haven't figured it out yet, I'd love to hear an easy answer.

I did learn that the bumper cover isn't all that tight on the core.  It's only like four little plastic press anchors that hold it on.  You can always drill new holes if you take off the plastic bumper strips (but that can split the bumper cover).  If you didn't want to use the old fashoined easy outs...I'd be tempted to pull the lights & cover off carefully, then chop away some of the bumper core to get at that bolt with vice grips or something.

That method might work unless you cracked the bolt off internally.  Then I'd go in with the easy outs.  Pain in the ass, but it's reliable.  Just keep drilling marginally larger holes with a lot of oil to cool the bits.  Don't bend them either.  If they snap you're totally screwed.

Repair any damage with plastic epoxy or even JB Weld & sanding.

[littleboyblues]

I was thinking is it possible to get at the screws that hold the bumper shocks in. Looking at some pictures looks like theres only two per shock and they face out. So ya...take off the bumper trim and lights and chop at the core. Maybe drill some holes?

Is that how the shocks are held in or are there other bolts and what not. That's all i got.

Dont really wana drill cause...its upside down. Would be taking a bath in the oil.

[gearheadE30]

I snapped one of those bolts off on a parts car. I never did get that bolt out; not with easyouts or anything. Ended up cutting the front of the car off with a sawzall to get at it from the back. Pulling the bumper cover and drilling holes would work to get the shock out, but its hard to get the cover off without removing the bumper. I'm not even sure it's entirely possible....

[DesktopDave]

I'd figure you might be able to remove the two shock bolts with the bumper on.  It'd depend heavily on the thickness of your wrench - that's a narrow space to work in.  Maybe a ratcheting box wrench?

[littleboyblues]

I got the bumper covers off and there's what looks like a fiber board like impact strip, i think its called. Fiber glass maybe. Looks like the only way to get at the bolts for the shocks would be to cut a square section out of the top of this piece.

Can you guys think of any reason why i shouldn't be doing this?

[DesktopDave]

No, I'd cut away as much as I needed to.  The cover will mask it all, and really doesn't need that much support.

[littleboyblues]

Alright thanks. I guess the only thing im kinda scared of is it just falling apart after a while. Guess i can just put a little fiberglass resin on the exposed place.

Think of it as a little weight reduction...lol.

[DesktopDave]

I wouldn't go crazy with it, just enough to get at the bolts.  I really prefer the plastic bumpers but the diving boards are so much easier to work with.

I'm surprised by that material, whatever it is...it's lighter than the diving boards and likely a tenth the cost.  If you've never had one apart you should see how pretty the alu welds are on the older cars.  Very expensive looking.

[littleboyblues]

I was thinking of cutting little semi circles or something to maybe keep some strength. But ya ill keep it simple.

Now that tell me about it i may just take an older one apart at the yard. Its what i do there anyways...my practice run for the real car at home.