The Damn Air Dam

I'm way behind on updates. The weather has been good and I pushed through to get the car ready to drive up to the Canadian Owners Conventions in Toronto. 

The air dam on the 99 Turbo is one of its most distinctive features. I think the original is made of ABS plastic. It tends to crack very easily and my was pretty seiously cracked. I found a fiberglass reproduction made by SAS as a replacement. The SAS kit does not come with the grille surrounds or mounting hardware so I recovered those pieces from the original. 

The old cracked dam in foreground and the SAS replacement behind it.  

 The hardware removed.  

Unfortunately, the grille surrounds were also cracked and would need to be repaired. Masked off the SAS air dam and taped the surround pieces into place. Where a large chunk section was missing I made walls to form a mold

I cut some pieces from the old air dam and ground up the plastic. By mixing this with some epoxy I was able to batch the missing sections. 

The repaired parts. 

I filed and sanded the excess epoxy. I sprayed primer on the air dam and surround separately then reassembled the pieces. My neighborhood pro auto painter sprayed epoxy black and a high gloss clear. The new air dam shines like the originals did when new. It also should be much more durable then the original ABS.