This year, just before Christmas, I decided I wanted to give me a present. So, I started by buying an used 2005 Volvo S60 rear bumper with all the brackets. So I searched the net, and in the end, I found one in Hungary at a salvage shop. After speaking several times with the owners of the shop, I went ahead and bought it, along with a pair of 2005 Volvo S60 tail lights, based on the pictures they sent me by mail:
However, they proved to be very deceitful and highly unprofessional. I ended up getting this piece of junk and no tail lights after nearly a month of waiting:
The sad truth: it wasn't even the same color as the one depicted in the photos they sent me
This was the "icing on the cake": broken plastic trim
After looking at it, I almost decided to drop the entire project, the blog and everything. After almost a month of being constantly on the road, I managed to get the car to a specialist shop, where my muffler was cut down. A few days later, my new tips arrived, so we started by changing the rear bumper. We did this for 2 reasons. First, my obsession of updating the looks of the car to the newer P2 Volvo S60. Second, it was much easier to cut the hole in that spoiler for the right hand exhaust tip.
Original bumper off
The conversion of the rear bumper is very easy if you have the side brackets. They are needed to ensure a perfect fit. Even with the '02 brackets installed you can mount the newer bumper, but the fitting will be a little off.
I'll cover the rear bumper conversion in another post in the DIY section.
What followed was a lot of welding.
The split for the dual exhaust
The split installed
Measuring the clearance of the new left exhaust tip
Final position of the exhaust tip
Left side tacked into position
The rear bumper was then cut to match the left side, and the exhaust pipe was tacked also into position.
All it took was to finish welding all the parts together and presto:
The main advantage of this system over the commercial ones like I mentioned in my wish list is that the exhaust coming out of the dual pipes is equal or symmetrical
In January I will take the rear bumper back to the specialist shop for repairs and paint and I will keep you posted. Till then, one last picture:
I will end this post wishing you all, a Merry Blessed Christmas and A Brand New Year full with wishes that will come true!
Safe journeys everyone!
UPDATE: 25.01.2014
Hello all!
I managed to fix and paint the bumper at a specialist shop. Now, the rear end transformation is almost complete. All I need now is to rebadge the car with the new spread VOLVO lettering and a pair of 2005+ rear lights.
Leaving the shop
At home, in the garage
Safe journeys everyone!
That looks pretty damn nice .
ReplyDeleteMersi, dragule!
DeleteE chiar fain blogul tau Andikoo :D! Mult succes iti doresc!
ReplyDeleteRenata ;))
Multumesc!
DeleteWow. I can only imagine what a horrible experience you had with that dealer. They really should be more professional in dealing with customers. Anyway, I like what you have done with your new bumper and I'm certainly looking forward to more of your projects on your Volvo.
ReplyDeleteDavid "Woody" Woodall
Thank you! Right now I have a few plans. I hope to finish the aesthetics this year and maybe start buying the hardware for the engine tuning.
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ReplyDeleteDid you manage to fit the face lift tail lights and did you need to rewire them?
ReplyDeleteThe tail lights are still the stock ones since the parts shop lied about having them on stock, so I abandoned the idea. However stay tuned, very soon a new pair of tail lights will arrive by mail and I will post again. The new tail lights are a plug and play upgrade (no rewiring needed).
DeleteWhat country are you in? How did splitting the exhaust effect your emissions, horse power, torque? Did you apply a cold air intake to accommodate the increased exhaust?
ReplyDeleteHi! I'm from Romania. Except emissions, which are unmodified, I didn't test the HP and torque for the simple reason that there is no dyno close to where I live, at least not a reliable one. I still have planned to fit a Fmic, cold air intake and chip tune, but that is in the future.
DeleteI want to install symmetrical duals on my 2002 S60t, can you send me details about the actual bumper cutting and what I need to deal with when I split the resonator out?
ReplyDeleteHi El, the bumper cutting is quite easy, you just have to measure the original hole and make another mirrored on the other side. My resonator is still in place, I only deleted the muffler, so I don't have details about that. I would recommend to go to a professional shop for your exhaust.
DeleteThanks. What cutting tool is best?
ReplyDeleteMostly done the duals, just need to tidy the bumper cutout. ALSO, my resonator needs replacing,....want one with better sound. Thoughts?
ReplyDeleteHi EL, glad everything is going nicely. Since I didn't delete my resonator, I can't give you firsthand advice. There are a few on the market, but I wouldn't buy one that is super cheap.
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