ok i have a 97 stock base bumper i want to fill in some of the mouth of the bumper so all u see thew the bumper is the intercooler what would be the best stuff to use and the best way to go about doing this

I would get some sheets of ABS or urethane, and use a heat gun to mold it into shape. Or you could always make a fiberglass "filler panel" then attach it.

As far as attaching the piece (I'm assuming you want it seamless so it looks like it was made that way?), I use 3M Speed Grip Urethane Structural Adhesive, and a lot of guys on here like Fuzor. Both are two part bonding epoxies...I've had a lot of success with them so far. Basically strip the paint off the bumper in the area you are going to make the bond (right down to the raw plastic), then rough up right where you are going to lay the epoxy, use some 60grit paper so the epoxy has something to bite to. Lay out the epoxy then put in your filler panel. I like over fill the epoxy a bit then taper down the edges on both sides to help blend them together. Once it dries, you can sand the epoxy smooth and feather the two surfaces together. If need be to level it out, lay down a skim coat of filler (just not too much since the plastic is flexible and filler isn't really, can lead to cracking later)...if you need filler, just be sure to hit the raw plastic with adhesion promoter and primer first, as filler won't stock to raw plastics for very long.

if i had a picture i can help you more
but here is what i would do for plastic

any time you have plastic is should be identified first, find the iso tage, polyurathene plastic is always yellow in color, the rest are black, but ya need to find this TPO/TPE/TEO/PP never do we fix or customize ABS plastic, like the saturns are btw complete junk too ok...............


he is right and some wrong info here is the right way, once the plastic both sides of the plastic are lightly ground down to the raw plastic, ya have to clean with either a plastic cleaner or plastic solvent, or amonina free glass cleaner, the only plastics that need adheshion promoter are TPO/TPE/TEO/PP those are offlien thermo set plastics once the adheshion promoter is dry in 15 mins then you can continue with the repair

there is no need for primer, primer comes after the repair is done, once you use lets say a fusor product, then lets say you do what this guy says to do, you apply a "bondo" over a plastic repair material its going to crack right off, lift, not bond, when you put primer on its going to lift


once a plastic repair material is used thats what you have to use through out the entire process, evercoat does make a plastic flexable "bondo" i only use it for small imperfections, but again the offlien plastics need adheshion promoter for anything to stick


can i haz bondo