DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

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maxpham
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DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby maxpham » Sat Nov 02, 2013 1:22 am


Obligatory Warning/Safety Statement
Although the installation steps outlined below works for me, it may not work for you. Do remember to wear personal protective equipment while drilling orifices, use properly rated jack stands to support your car, and ensure you have ample lighting. Road conditions and driving styles differ from area to area, person to person so the steps here may not be best for you. Also, I am not a professional (by any meaning of that word), I do not profit from any of the vendor links provided below. I am just a do-it-yourself'er like yourself; please don't sue me.
:roll:

Required Materials
  1. JDM Kouki Trueno Front Bumper (PN 52119-12092) ~$450USD
  2. JDM Zenki Trueno Front Spoiler (PN 76081-12020) ~$260USD
  3. 1.5" Corner Brace (Stainless Steel 4 Pack) ~$5USD
  4. M6x1.0 25mm Bolts (x4) ~$2USD
  5. M6x1.0 25mm Nuts (x12) [i]~$4USD
  6. M5x0.8 25mm Bolts (x2) [i]~$1USD
  7. 1/4" Lockwashers (x4) [i]~$3USD
  8. 1/4" Rubber Washers (x8) [i]~$3USD

Tools
  1. Portable Drill + Drill set
  2. Vise
  3. Ratchet + 10,12mm sockets
  4. Jackstands (x4)
  5. Jack
  6. Worklight
  7. Tape
  8. (optional) Dremel w/metal cutting disc
  9. Appropriate Ambience

Time Required: ~30-45 minutes

Preparation
  1. Use the jack to lift your car up to a comfortable working height. Although you only need to lift up the front, I found that lifting all four corners to a level height is ideal.
  2. Purely optional and based heavily on preference, paint the lip.
    Image
  3. The corner braces have orifices that do not fit the M6x1.0 bolts, this is where you mount the braces on a vise and drill holes to accommodate the bolts. For my application, I expanded one orifice nearest the corner and dremel'ed the opposite end's two holes together. This gives me room to adjust.
    Image
  4. Parts Check: If you bought the lip new, it should come with these 6 bolts and 4 spacers. You only need to use 4 of the bolts to mount the lip. If not, you will need to purchase 4 additional M6x1.0 25mm bolts with a square nut.
    Image

Installation
  1. Hit the Appropriate Ambience and let's get to it.
    Image
  2. Stick four of the bolts that came with the spoiler at the outer ends and in the middle (positions 1,3,4,6).
  3. Screw in a nut, washer, and the adjustable end of the corner brace to a bolt like this:
    Image
  4. Repeat previous step until it looks like this:
    Image
  5. You should apply some tape and mount the zenki to your kouki. Special note, the zenki lip does not reach the wheel well. You can sand down your kouki bumper to be flush if this bothers you. I'm in Hawaii, so not many things bother me.
    Image
  6. Align the braces to be flush with the lower part of your kouki, mark off your intentions, and drill baby drill!
  7. Stick one of those M6x1.0 25mm bad boys on and screw nuts + washers in place. Do this four times.
    Image
  8. The front is now fairly stable but the sides need some work. This is where the two M5x0.8 bolts come in play. You'll notice that these bolts can thread the top left orifice rather nicely...
    Image
  9. Mark off the adjacent area on the kouki bumper and drill a hole there to feed the bolt through like so:
    Image
  10. Use a bit of elbow grease to work the bolt into the zenki lip like this:
    Image
  11. Repeat this for the other side.
    Image
  12. Remove the tape and check/tighten the nuts & bolts.
    Image
    Image
  13. Lower the car from the jackstands, take a dramatic photo of your lip, and post it to this thread. :D
    Image

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Zissou
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby Zissou » Sat Nov 02, 2013 11:39 am

Nice write up, the car looks great.

marley4us
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby marley4us » Sat Nov 02, 2013 2:45 pm

nice looks amazing!

Did I sell you those CF fender flares? they look so bad ass on ur car!! more pics of ur beast!
1985 Corolla Hatch widebody w/ SR20det (The Project)
1993 5SGTE stroker widebody MR2 Turbo (drag car)
2002 Miata SE hardtop (daily Driver)
1994 4runner (The truck)

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maxpham
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby maxpham » Sat Nov 02, 2013 4:03 pm

Yeah you did Ian! It's not done yet. I promise in a week, maybe two. :)

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TORPARTS
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby TORPARTS » Sat Nov 02, 2013 4:58 pm

Duma approved! One of best hatch period! Send me pics sir!

Mahalo!
http://www.torparts.com
WORLD LEADER IN REPRODUCTION, OEM AND JDM PARTS.

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maxpham
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby maxpham » Sun Nov 03, 2013 3:54 pm

Will do with the pics. Soon I promise!

ryceboy_124
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby ryceboy_124 » Tue Nov 26, 2013 7:31 pm

Awesome write-up Max!!! Looks awesome bro...

sekang0
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby sekang0 » Wed Nov 27, 2013 4:34 pm

Nice write up bro. Gotta do this soon.
'85 GT-S project since 2010
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idreamofdrifting
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby idreamofdrifting » Wed Feb 19, 2014 1:22 am

Very nice DIY Keep it up!
"If my Memes bother you, you're taking life way too seriously!"
~Me~

"RICE=Racing Inspired Cosmetic Enhancments"
~ga_goosh~


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EvoSolley
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby EvoSolley » Tue Mar 11, 2014 8:04 pm

Your DIY helped me through the install with flying colors!! Thanks maxpham!!!

Image

Image

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maxpham
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby maxpham » Fri Mar 14, 2014 10:19 pm

That looks great! Glad I played a small role in that.

TORPARTS
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby TORPARTS » Sat Oct 18, 2014 12:27 pm

DUMA APPROVED!
http://www.torparts.com
WORLD LEADER IN REPRODUCTION, OEM AND JDM PARTS.

Erik_drift10
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Re: DIY: Zenki Lip on Kouki Bumper (JDM Trueno)

Postby Erik_drift10 » Thu May 28, 2015 6:00 pm

Noob question but i have a zenki front bumper and purchased the zenki lip. How hard is it to install the lip on the zenki bumper? Would i need to drill holes in the bumper?

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