Clamped in place, one half of the side section looks like it fits fine. From here the top and bottom side section pieces are welded together.
All five pieces (sides, corners, and centersection) are then welded together, and the welds are as clean inside as they are outside.
Marc finishes the bumper by fabricating mounting brackets on both the center section and the ends, placing them in the same locations as on the original bumper.
Side by side, you can see how close the new bumper and the original are. Have you figured out the application yet? The bumper is for a '60s-era Maserati, although, as noted earlier, Marcel's methods could be used to build all kinds of custom parts. Any brave souls out there?
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.