Both dies are mounted into the Piccolo, and you can see what shape they will create. Note the tab at the back of the die-this is a stop guide for the edge of the metal that will be fed through the dies.
You can get the curve of a bumper (how it fits around the back half of a body) two ways. The hard way is to cut a straight piece of metal, then stretch it so it gets the right curve. The easy way is to cut the section with the curve already in it, then just form the edge. Using the second method, Marc and Marcel then fed the curved section through the dies.
What you get is a slightly curved center section (which follows the car body) with a lip formed over one edge. Two of these center section pieces are made-one for the top, one for the bottom.
Again using the old bumper as a form, the two sections are clamped in place before Marc begins to tack them together. Marcel keeps an eye on the sections so they fit together perfectly.
The top and bottom sections look like this after the seam is welded.
Marcel then grinds the welds to create a peak that runs the length of the bumper.
Once the center section and corners are made, they get clamped together over the old bumper. All sections are intentionally made a little too long or too wide, so Marc uses a scribe to show where cuts need to be made to fit the pieces together.
Marc trims the excess metal off each piece using hand shears.