Review And Installation Of Kbd Polyurethane Body Kits On A 240sx

So, you're thinking about installing a KBD Polyurethane body kit on your 240SX? Excellent choice! Polyurethane offers a fantastic balance of durability and flexibility, making it a great upgrade for these cars. However, it's not always a straightforward bolt-on affair. This article will guide you through a common problem encountered with KBD kits – fitment issues – and offer practical solutions to ensure a successful installation.

The Dreaded Fitment Problem: Why Does It Happen?

Let's be honest, perfect fitment with aftermarket body kits, especially on older vehicles like the 240SX, is rarely a given. Here's why you might encounter issues with your KBD kit:

• Manufacturing Tolerances: Polyurethane molding, while generally accurate, can still have slight variations. These small differences can accumulate, leading to gaps or misalignment.
• Vehicle History: Your 240SX has likely lived a long life. Previous accidents, even minor ones, can subtly alter the chassis, affecting how the kit aligns. Rust repair, even done well, can also influence panel gaps.
• Shipping and Storage: While KBD uses good packaging, sometimes parts can get slightly warped during shipping or improper storage. Heat can definitely impact the shape of polyurethane over time.
• Expectations vs. Reality: This isn’t LEGO. Minor adjustments are always expected with aftermarket body kits. Accepting this from the start saves a lot of frustration.

Identifying and Addressing Fitment Problems

Before you even think about paint, thorough test fitting is crucial. Here's how to approach it:

Step 1: Unboxing and Initial Inspection

Carefully unbox all the kit components. Check for any obvious damage from shipping – cracks, tears, or significant warps. Contact KBD immediately if you find anything concerning. Take pictures for documentation.

Step 2: Parts Inventory and Identification

Compare the parts you received against the included parts list (if any). Familiarize yourself with each piece. Knowing what goes where is half the battle.

Step 3: Test Fitting (The Key to Success)

This is where the magic (or frustration) happens. Gather the following tools:

• Jack and jack stands
• Basic hand tools (sockets, wrenches, screwdrivers)
• Masking tape (a lot of it)
• Clamps (various sizes)
• Heat gun (optional, but highly recommended)
• Sharp utility knife or razor blade
• Sanding block and sandpaper (various grits)
• Drill and drill bits
• Marker or grease pencil

Start with the largest parts, typically the front and rear bumpers, followed by side skirts. Here's a general process:

1. Prepare the Vehicle: Ensure your 240SX is safely supported on jack stands. Remove the existing bumper covers and side skirts.
2. Position the Part: Carefully position the KBD part onto the vehicle. Use masking tape to temporarily hold it in place. Don't force anything!
3. Identify Problem Areas: Look closely for gaps, overlaps, or misalignment. Pay attention to mounting points (where the kit attaches to the vehicle). Use your marker to clearly identify problem areas on both the kit and the car.
4. Repeat for All Parts: Work your way through each component of the kit, noting any issues.

Common Fitment Issues and Solutions

Here are some of the most frequently encountered problems and how to tackle them:

Gaps Between Parts and the Body

Cause: This is often due to slight variations in the polyurethane molding or minor chassis discrepancies.

Solution:

• Heat Gun Manipulation: This is your best friend. Gently heat the polyurethane in the affected area and carefully push or pull it into the desired shape. Hold it in place with clamps until it cools. Be patient and work in small increments to avoid overheating and damaging the material. Always wear heat-resistant gloves.
• Sanding/Grinding: If there's an overlap, carefully sand or grind down the polyurethane material until it sits flush. Start with a coarser grit sandpaper and gradually move to finer grits for a smooth finish. A Dremel tool with a sanding attachment can be helpful for small areas.
• Shimming: For small gaps, consider using thin plastic shims (available at most hardware stores) to fill the space. These can be bonded in place with polyurethane adhesive.

Misaligned Mounting Points

Cause: This often stems from minor differences in the mounting hole locations on the kit versus the factory mounting points on the 240SX.

Solution:

• Enlarging Mounting Holes: Carefully enlarge the mounting holes on the KBD kit using a drill. This allows for some wiggle room and adjustment.
• Creating New Mounting Points: In some cases, you might need to create new mounting points on the kit or the vehicle. This typically involves drilling new holes and using bolts, nuts, and washers to secure the part. Be sure to protect any bare metal from rust afterwards.
• Polyurethane Adhesive: For areas where drilling isn’t possible, high-strength polyurethane adhesive can be used to bond the kit to the body. Follow the adhesive manufacturer's instructions carefully. This is especially useful for side skirts.

Warped or Bent Parts

Cause: Shipping damage or improper storage can cause polyurethane parts to warp or bend.

Solution:

• Heat Gun and Clamps: Similar to addressing gaps, use a heat gun to gently warm the warped area and then clamp the part into the correct shape until it cools. It may take multiple attempts to achieve the desired result.
• Weight and Time: In some cases, simply placing a heavy object on the warped area for an extended period (days or even weeks) can help it to return to its original shape.

Side Skirt Sagging

Cause: Due to their length and flexibility, side skirts can sometimes sag in the middle, creating an unsightly gap between the skirt and the rocker panel.

Solution:

• Additional Mounting Points: Add additional mounting points along the length of the side skirt. This can be done by drilling holes through the skirt and rocker panel and using bolts and nuts to secure them.
• Polyurethane Adhesive: A liberal application of polyurethane adhesive along the length of the skirt can also help to keep it flush with the rocker panel.
• Internal Support: Consider adding a lightweight internal support structure to the side skirt. This could be made from metal or fiberglass.

Important Considerations Before Painting

Once you're satisfied with the fitment, there are a few more things to consider before sending your KBD kit off to the paint shop:

• Surface Preparation: Polyurethane needs proper surface preparation for paint to adhere correctly. This typically involves sanding the entire surface with progressively finer grits of sandpaper and applying a polyurethane-specific primer.
• Flex Agent: Talk to your painter about adding a flex agent to the paint. This helps prevent the paint from cracking if the polyurethane flexes or bends.
• Professional Installation Recommended (But Not Mandatory): While it's possible to install a KBD kit yourself, professional installation by an experienced body shop is highly recommended. They have the tools, experience, and expertise to ensure a high-quality, long-lasting finish.

Cost Considerations

Here's a rough estimate of the costs involved in installing a KBD Polyurethane body kit on your 240SX:

• KBD Body Kit: $400 - $800 (depending on the kit)
• Tools and Supplies: $50 - $200 (if you don't already own them)
• Paint and Materials: $300 - $600 (depending on the color and quality of paint)
• Professional Installation (including fitment and painting): $800 - $2000 (this can vary widely depending on the shop and the complexity of the installation)

DIY Installation (excluding paint): $450 - $1000

Professional Installation (including paint): $1500 - $3400

Remember to factor in potential hidden costs, such as rust repair or additional parts that might be needed.

Final Thoughts

Installing a KBD Polyurethane body kit on your 240SX can be a rewarding experience. While it might require some patience and problem-solving, the end result is a unique and stylish upgrade that will set your car apart. By following the steps outlined in this article and taking your time, you can achieve a professional-looking installation that you'll be proud of. Good luck, and happy modding!