How to unbend aluminum bumper

[BigR]

It took a couple of days to make the patterns, adjusting and fitting, then removing the old bumper brackets, etc. The prep work, assembling the press, cutting the wood, making the wood triangles, figgern' everything out took another half day.

The actual bending only took a half hour or so. I think I made maybe a half dozen tries. What surprised me was the amount of distance the metal needed to be moved before it took a set. These bumpers were nice and thick and I was careful to spread the pressure to the left and right of center, not working the same area over and over. Resulting curve is smooth, with no discontinuities.

Now I need to bend the ends more "inward" to conform to the curve of the car fenders. I want to keep the distance from the body consistent the full length of the bumper.

[smallfoot]

Does sound to me to be a good plan of attack!

[Bamamav]

I thought that would work. Just like reversing the eyes on a leaf spring, just not going as far. You do have to go past where you want it to let it spring back a bit.

[BigR]

Finished bending and cutting the rear bumper. I had to add more curve outbioard to match the fenders. This time I weighted down the press with a motorcycle jack, concrete filled coffee can and a bench vise.

Cut 5 inches off each end. Rounded off and polished one end then just had to put it on the car and take pics. Looks pretty good, if I do say so myself.