Jet Jockey/A4 Pilot

So here we go again for another round of the extreme weight reduction program and this time we are attacking the front are rear bumpers. Let’s start with the rear because that was an easy job to do.


BAM! That was easy… Rear bumper gone, removed for ever.




Well that was too easy but heck it is 19 lbs!




Now for the front bumper assembly. Here it is removed for the engine removal.





Here’s the heaviest part of the whole bumper assembly, the bumper shock absorbers.




Both of them were removed. 12.8 lbs together, nice! So bye bye to them.




What’s left of the actual aluminium rebar or front bumper. It was modified for the FMIC.




So now we had to make a substitute assembly for the front bumper shock absorbers. We started with a ¼ inch aluminium plate. We cut it to the exact shape needed to fit in the location of the OE shock absorbers.




Here it is in the proper location.




Then we needed to replace the actual shock absorber. So we used some aluminium tubing and some aluminium rod. The rod was hollowed out so that a bolt could fit through it as in the OE assembly.



Here’s the tubing cut to the appropriate length and the rod too.




Close up.



Here we have the assembly once the tubing is welded to the plate and some reinforcement brackets are installed. The aluminium rod is also welded in place.
Only 1.3 lbs.




Another angle of the new bumper support.



Here it is in its proper location.