Installation of KBD Body Kits Porsche GT 3 Look/Style 2 Piece Polyurethane Front Bumper & Lip Applications: Porsche 996: 1999-2001 Porsche Boxster 986: 1997-2004 Page 1 Tools Needed: Philips Head Screwdriver Flat Head Screwdriver Needle Nose Pliers Section 1: Getting Started Removing OEM Front Bumper BEFORE
Page 2 Section 1 Cont. 1) Start by raising your front hood/trunk 2) Using your Flat Head Screwdriver, turn the (4) Plastic Retaining Clips ¼ turn to the left to release 3) Using your Flat Head Screwdriver, pry up on these (4) Plastic Retaining Clips until they pop out of their socket 4) Remove the black plastic cover that was held in place with these Retaining Clips 5) Using your Philips Head Screwdriver, remove the (2) 19mm Philips Head Screws holding the Bumper Support Bracket
Page 3 Section 1 Cont. 6) Remove both Passenger & Driver side Marker Lights by pulling on the end closest to the wheel 7) Disconnect light socket attached to marker lights to remove entire light 8) Using your Philips Head Screwdriver, remove the 19mm Philips head screw that is behind the marker light [Repeat for both sides] 9) For this next step, turn your wheels all the way to the left until wheel lock, this will give easier access to the next screw removal
Page 4 Section 1 Cont. 10) Using your Flat Head Screwdriver, pry up the two rivets on the wheel well [Repeat for both sides] 11) Once the rivet is far enough out, use your Needle Nose Pliers to pull the rivet completely out 12) Pull back the plastic wheel well lining, giving you access to the internals of the front bumper [Repeat for both sides]
Section 1 Cont. Page 5 13) While holding back the wheel well lining, use your Philips Head Screwdriver to remove the 19mm screw underneath the marker lights (this is the most difficult to access) [Repeat for both sides] 14) Using your Philips Head Screwdriver, remove the (9) total Philips Head Screws holding the bumper onto the support brackets underneath the front bumper (8) Total 22mm Philips head screws [Sides] (1) Total 28mm Philips head screws [Middle] Note: You will need a short Philips head screwdriver if your vehicle is not jacked up
Section 1 Cont. Page 6 15) Standing in front of your vehicle, gently grab the front bumper on the top center and pull toward yourself. Your bumper should come off with ease. Note: With your front bumper off, this is a great time to clean your radiators
Page 7 Section 2: Unfolding & Prepping Bumper Tools Needed: Hand Dremel Permanent Marker (Not Black) Heavy Duty Scissors Drill ¼ inch Drill Bit 15 Fasteners (If Installing Bottom Lip) Heated Room Clear Tape Unboxing & Forming Bumper Congratulations! You are now the new proud owner of a KBD front Bumper Cover & Lip 1) Start by removing the Bumper Cover & Lip from shipping box, place in a heated room/heat source for a minimum of 20-30 minutes or until your Bumper and Lip take shape.
Section 2 Cont. Prepping &Trimming Bumper Cover Page 8 1) Place your new bumper alongside your OEM Bumper Cover and examine OEM Bolt holes/cut outs. 2) With your Permanent Marker, begin tracing the areas that need to be cut out (Most will be marked from KBD themselves in the mold)
Page 9 Section 2 Cont. 3) If you want to match OEM bumper specifications, apply clear tape to the OEM Bumper Cover in areas you would like to copy. Using your permanent marker, trace the cut outs/bolt holes desired. 4) Transfer the clear tape to your new bumper and align tape with the premarked cut outs.
Page 10 Section 2 Cont. 5) Using your heavy duty scissors, trim as much of the traced lines as you can. Then using the hand dremel, sand down the rough edges to give it a clean, professional look. (Repeat for top & bottom) 6) Using your drill & ¼ inch drill bit, drill all marked holes on the top and bottom of the bumper cover
Page 11 Section 2 Cont. For Bottom Bumper Lip Only 7) With your bumper upside down, place the lower lip on top of the bumper where it should sit when installed. 8) Check both edges to make sure the bottom lip is in the correct place. (Use tape to hold bottom lip on bumper if needed) 9) Using your drill and ¼ inch drill bit; starting from the center and working outward, drill through the bottom lip & bumper. (9 total holes) Insert fastener of choice to hold the lip in the correct place
Page 12 Note: Leave the last three taps on each side un-drilled Section 2 Cont. 10) Using your permanent marker, mark the edges of the bumper cover where the 3 tabs need to be inserted, then using your hand dremel, make cutouts that will allow the bottom lip to be inserted into the bumper cover. (Repeat for both sides)
Page 13 11) Using your hand drill and ¼ inch drill bit, drill through the bottom lip & bumper cover until the last remaining (3) tabs on each side are complete. (6 total holes) Note: Using the fasteners of your choice, fasten the last 6 holes.
Page 14 Section 3: Test Fitting Your Bumper Tools Needed: Philips Head Screwdriver Permanent Marker 1) Start by using your Philips Head Screwdriver to install the top (2) 19mm Philips head screws to hold your bumper in place.
Section 3 Cont. 2) Once secured on the top, using your Philips Head Screwdriver, install as many Philips Head Screws as you can on the bottom of your bumper. Page 15 Note: Any hole that does not line-up, using your Permanent Marker, mark where modifications need to be made. 3) Moving to the side marker location, using your Permanent Marker, mark where the holes need to be drilled to install the bumper correctly.
Page 16 Section 3 Cont. 4) Remove your bumper, and make the final modifications needed before your bumper is painted to avoid cutting/trimming when painted. Congratulations, it is now time to paint or send off the bumper to get painted!
Page 17 Tools Needed: Section 4: Installing Your Bumper Philips Head Screwdriver Heavy Duty Scissors (If Installing Mesh) Flat Head Screwdriver Installing Mesh 1) If you are installing Mesh in your intake holes, start by laying your Polyurethane Mesh over the intake holes, and using your Heavy Duty Scissors to cut according to size. 2) Secure the Polyurethane Mesh to the intake holes using your own preferred method. (Screws, Glue, etc.) Note: Below provides a successful way Hardware Used to Secure Mesh -Clear Flexible Construction Adhesive -Stainless Steel Clevis Pins
Page 18 Section 4 Cont. Installing Bottom Lip 3) Secure the bottom lip to your bumper using the pre-existing holes. Use the fasteners of your choice (Below is the hardware recommended) Hardware Used to Secure Bottom Lip (12) Flat Philips Head Stainless Steel Bolts [Size #8] ¾ inch long (24) Flat Stainless Steel Washers [Size #8] (12) Stainless Steel Nylon Insert Nuts [Size #8]
Page 19 Section 4 Cont. Installing Your Bumper 4) Using your Philips Head Screwdriver, install the top (2) Philips Heads 19mm screws to hold your bumper in place. 5) Using your Philips Head Screwdriver, install the center (3) Philips Head Screws on the bottom of your bumper. (1) 28mm Philips Head Screw (Center) (2) 22mm Philips Head Screws (Left & Right)
Section 4 Cont. 6) Using your Philips Head Screwdriver, install the (2) 19mm Philips Head screws in both your side marker locations. (Repeat For Both Sides) Note: The bottom screw needs to be accessed through the wheel well Page 20 7) Install the two Pop-Rivets in the wheel well by simply pushing the pin with your finger until flush. (Repeat for Both Sides)
Section 4 Cont. 8) Using your Philips Head Screwdriver, install the (2) 22mm Philips Head screws closest to the wheels on the bottom of your bumper. (Repeat for Both Sides) Page 21 9) Install your top finish plate, then using your Flat Head Screwdriver, turn the (4) plastic retaining clips ¼ turn to the right to secure them in place.
Section 4 Cont. 10) Secure your temp sensor using your own method, I was able to pull mine thru the mesh using Needle Nose Pliers. Page 22 11) Install your new 997 Side Markers by inserting the front clips and simply pushing in on the back until you hear a Click noise.
Congratulations! Page 23 Your new KBD Body Kits Porsche GT 3 Look/Style 1 Piece Polyurethane Front Bumper & Lip should now be installed! After