Application Of The Rocket Bunny Aero Kit To The 240sx Convertible

So, you're thinking about slapping a Rocket Bunny aero kit onto your 240SX convertible, huh? Good choice. It’s a transformative upgrade, taking that already sleek S13 silhouette and cranking it up to eleven. But let’s be real, this isn't a bolt-on affair like swapping out air filters. This requires careful planning, precision, and a solid understanding of bodywork. This article is your no-nonsense guide to tackling this project.

Pre-Installation Considerations

Before you even think about ordering that Rocket Bunny kit, let's get a few things straight. This isn't a weekend project for the faint of heart. We're talking about cutting, drilling, and permanently altering your car. Seriously, consider these points:

1. Body Condition

Is your 240SX structurally sound? Rust, especially around the wheel wells and rocker panels, can compromise the structural integrity required for properly mounting the kit. Address any rust issues before you even think about the aero kit. Reinforcements might be necessary if the rust is severe.

2. Kit Quality and Authenticity

Rocket Bunny is a specific brand (now Pandem). There are plenty of replica kits out there. While some replicas are decent, the fit and finish are almost always inferior to the real deal. Expect to spend more time and effort massaging a replica kit into place. Consider the source and material. Real Rocket Bunny kits are typically made of FRP (Fiber Reinforced Polymer) which is a combination of resin and reinforcing fibers like fiberglass. Inferior kits use thinner FRP or other less durable materials.

3. Legality and Regulations

Depending on where you live, widened fenders and body modifications might raise eyebrows with local authorities. Check your local laws regarding vehicle modifications. Projecting tires beyond the fender line, for example, can be a violation.

4. Budget

The cost of the kit itself is just the tip of the iceberg. Factor in the cost of:

• Professional installation (if you're not confident in your abilities)
• Bodywork tools (if you don't already have them)
• Paint and materials
• New wheels and tires (likely needed to fill the wider fenders)
• Possible suspension adjustments to accommodate the new wheel/tire setup

Tools and Materials

Here’s a general list of what you’ll need. Adapt this based on the specific instructions that come with your kit and your own experience.

• Safety Gear: Safety glasses, gloves, respirator (especially when sanding)
• Cutting Tools: Angle grinder with cutting discs, reciprocating saw (Sawzall), Dremel tool with cutting bits
• Grinding and Sanding Tools: Angle grinder with flap discs, various grits of sandpaper (80, 120, 220, 320, 400), sanding blocks
• Measuring and Marking Tools: Tape measure, markers, masking tape, straight edge
• Fastening Tools: Drill with various bits, rivet gun, pop rivets, screws, nuts, washers
• Bodywork Tools: Body filler (Bondo), spreader, body hammers, dolly set
• Adhesives: Panel bonding adhesive (e.g., 3M Panel Bonding Adhesive), silicone sealant
• Painting Supplies: Primer, paint, clear coat, spray guns (optional, can use aerosol cans), masking paper, tack cloth

Installation Steps (General Guide)

Disclaimer: This is a general overview. Always refer to the specific instructions that come with your Rocket Bunny kit. Each kit has its own nuances and mounting points.

1. Preparation is Key

Thoroughly clean the car. Remove any trim, moldings, or parts that will interfere with the installation. Mask off areas you don't want to accidentally damage. Take a bunch of pictures of the car before you start cutting anything. You might need to refer back to them later.

2. Test Fitting

This is arguably the most important step. Before you commit to any cutting, carefully test fit each piece of the kit. Check for any major gaps or fitment issues. Identify where you'll need to trim or modify the kit. Don't be afraid to spend hours on this step. The better the fit now, the easier the rest of the process will be.

3. Cutting and Trimming

This is where things get real. Using your cutting tools, carefully cut away the existing fenders to accommodate the over-fenders. Take your time and err on the side of caution. You can always remove more material later, but you can't put it back on. Use masking tape as a guide to create clean, straight cuts. The goal is to create a space large enough to accomodate the new wider fenders. Be sure to leave enough space for inner fender mounting.

Important Note: When cutting, be mindful of any wiring harnesses, brake lines, or fuel lines behind the sheet metal. Damage to these components can be catastrophic.

4. Mounting the Over-Fenders

The mounting method will vary depending on the kit. Some kits use rivets, some use screws, and some use a combination of both. Some kits require panel bonding adhesive for added strength and a seamless look. Follow the instructions carefully. Pre-drill all holes before riveting or screwing anything in. Use clamps to hold the over-fenders in place while you drill.

5. Bodywork and Filling Gaps

Even with a genuine Rocket Bunny kit, you'll likely have some gaps between the over-fenders and the body. Use body filler to fill these gaps and create a smooth, seamless transition. Sand the filler smooth and feather it into the surrounding paint. This is where your bodywork skills will be put to the test.

6. Smoothing and Preparation for Paint

Proper preparation is paramount for an excellent paint job. Even if you're not painting immediately, it's essential to smooth out any imperfections and feather edges using progressively finer sandpaper. Start with a coarser grit (like 180 or 220) to address larger imperfections, then gradually move to finer grits (like 320, 400, and even 600) to create a smooth surface. Remember to wet sand between each grit change to prevent clogging the sandpaper and create a smoother finish. Degrease the surface thoroughly before priming, using a wax and grease remover. This ensures proper adhesion of the primer and paint.

7. Painting

Apply several coats of primer to the bodywork, sanding lightly between each coat. Then, apply several coats of paint, followed by several coats of clear coat. Allow each coat to dry completely before applying the next. Wet sand the clear coat to remove any imperfections and then polish it to a high shine. If you're using aerosol cans, be patient and apply thin, even coats to avoid runs and drips.

Expert Tip: Test the paint on a hidden area before applying it to the entire car. This will ensure that the color matches and that the paint adheres properly.

8. Reassembly and Final Touches

Reinstall any trim, moldings, or parts that you removed earlier. Install your new wheels and tires. Adjust the suspension as needed to achieve the desired ride height and stance. Step back and admire your handiwork.

Specific Considerations for Convertibles

Adding a Rocket Bunny kit to a convertible introduces a few unique challenges:

• Structural Rigidity: Convertibles inherently have less structural rigidity than coupes. Adding wide over-fenders can further compromise the chassis. Consider adding chassis bracing, such as a roll cage or strut tower braces, to improve rigidity.
• Soft Top Clearance: Make sure the over-fenders don't interfere with the operation of the soft top. You might need to make minor adjustments to the kit or the soft top mechanism.
• Aesthetics: The aggressive look of the Rocket Bunny kit might clash with the more refined lines of a convertible. Consider how the kit will flow with the overall design of the car.

Troubleshooting

Inevitably, you'll encounter some problems along the way. Here are a few common issues and how to address them:

• Fitment Issues: If the kit doesn't fit properly, double-check your measurements and make sure you've cut the fenders correctly. You might need to use body filler to fill larger gaps.
• Rivets Pulling Through: If the rivets are pulling through the sheet metal, use larger rivets or add backing plates to reinforce the mounting points.
• Paint Runs: If you get paint runs, let the paint dry completely and then sand them down with fine-grit sandpaper.

Conclusion

Installing a Rocket Bunny aero kit on your 240SX convertible is a challenging but rewarding project. With careful planning, meticulous execution, and a bit of patience, you can transform your car into a head-turning masterpiece. Just remember to take your time, follow the instructions, and don't be afraid to ask for help when you need it. Good luck, and happy modding!