Making A Bad Boy Bonnet

Step 1

The two brows are made from 2-3mm thick sheet steel. These need to be 'roughly' triangular in shape with a rounded corner that fits into the fiestabonnet. Take your time with these, as the final shape will determine how your car looks.

Step 2

Once the rough shapes are made, the pieces need to be filed to size using a bench grinder. The final pieces should be identical in size and shape to each other. The bonnet edge around the lamps should be sanded back to bare metal to allow the welds to stick. You will have to bend the eyebrows slightly to make them follow the line of the bonnet. Hold the brows in place and make sure that you can open the bonnet all the way without them coming into contact with the headlamps. Also make sure you allow enough room should the headlamps ever need to be adjusted.

Step 3

The 'eyebrows' are then welded on from both sides. The welds on the outside are angle ground down to be flush with the existing bonnet line. Use fibre filler on the back to help give a little more strength, and normal body filler on the front to fill any gaps between the original bonnet edge and the brows. You can weld the brows on with an Arc welder, though if you have access to a Mig welder use that as it'll be easier to use.