Rocket Bunny V2 Boss Kit Installation Technical Manual

Alright folks, let's talk about the Rocket Bunny V2 Boss Kit. This isn't your average bolt-on fender flare; it’s a full-fledged aesthetic transformation. This manual assumes you have a solid understanding of basic automotive repair, including panel removal, cutting, and potentially some welding. If you're not comfortable with these tasks, seriously consider professional installation. We’re going to walk through the process step-by-step, covering the tools you'll need, the preparation required, the actual installation, and some common pitfalls to avoid.

Tools and Materials Required

Before you even think about touching your car, make sure you have everything on hand. Running to the store mid-project is a recipe for frustration. Here's a comprehensive list:

Complete Rocket Bunny V2 Boss Kit: This should include all fenders, side skirts, rear wing (if applicable), and mounting hardware. Double-check the inventory against the parts list.
High-Quality Cutting Tools: This is crucial. A rotary tool (like a Dremel) with reinforced cutting wheels is ideal. Body saws or air saws can also work, but require more finesse.
Measuring Tools: Tape measure, straight edge, and marking tools (Sharpies, masking tape). Precision is key.
Safety Gear: Eye protection (goggles or a face shield), ear protection, gloves, and a respirator mask (especially when cutting fiberglass).
Grinding and Sanding Tools: Angle grinder with grinding discs, sanding blocks (various grits), and sandpaper (80 grit to 400 grit).
Bodywork Tools: Body hammers, dollies, and potentially a stud welder for minor dent repair.
Welding Equipment (Optional but Recommended): A MIG welder is ideal for reinforcing cut areas and potentially fabricating custom brackets.
Riveting Tools (Recommended): A heavy-duty rivet gun and appropriate rivets for attaching the kit. Self-tapping screws can be used as a substitute, but rivets offer a cleaner, more durable finish.
Adhesive and Sealant: High-quality body panel adhesive (like 3M Panel Bonding Adhesive) and seam sealer.
Primer and Paint: Automotive primer, paint (matching your car's color or a custom color), clear coat, and all necessary painting supplies (spray gun, mixing cups, etc.).
Basic Hand Tools: Wrenches, sockets, screwdrivers, pliers, etc.
Jack and Jack Stands: For safely lifting and supporting the vehicle.
Wheel Chocks: Essential for safety.
Masking Paper and Tape: For protecting areas from overspray.
Cleaning Supplies: Degreaser, wax and grease remover.

Step 1: Preparation and Disassembly

This is where patience and meticulousness pay off. Don't rush this step. Proper preparation is paramount for a successful installation.

Safety First: Disconnect the negative terminal of your battery. This prevents accidental shorts during the process.
Vehicle Protection: Cover the surrounding areas of your car with drop cloths or protective sheeting. Sparks from grinding and cutting can easily damage paint.
Disassembly: Remove all necessary body panels. This typically includes the front and rear bumpers, side skirts, fenders, and potentially the inner fender liners. Keep all hardware organized and labeled to avoid confusion during reassembly. Take photos of everything as you disassemble.
Test Fitting: Absolutely crucial! Place the Rocket Bunny kit pieces on your car to assess the fitment. Look for any major discrepancies or areas that need adjustment. This is the time to identify potential problems and plan your approach. Do not assume everything will line up perfectly. Fiberglass kits often require some tweaking.
Marking: Using a Sharpie and masking tape, carefully mark the areas where you will need to cut the original fenders. Follow the Rocket Bunny kit's instructions closely, but also use your judgment. Aim to cut slightly less than you think you need to, as you can always remove more material later.

Step 2: Cutting and Grinding

This is the point of no return, so take your time and double-check your measurements before committing to any cuts.

Cutting: Using your chosen cutting tool, carefully cut along the marked lines. Wear your safety gear! Small, controlled cuts are better than large, aggressive ones. Allow the tool to do the work; don't force it.
Inner Fender Modification: Pay close attention to the inner fender liners. They will likely need to be trimmed or completely removed to accommodate the wider fenders. Consider re-routing any wiring harnesses or brake lines that might interfere with the new fenders.
Grinding: Once you've made your cuts, use an angle grinder with a grinding disc to smooth the edges and remove any sharp burs. This is important for both safety and aesthetics. Aim for a smooth, even surface.
Rust Prevention: Any exposed metal should be treated with a rust-preventative primer. This is crucial to prevent corrosion.

Step 3: Fitting and Adjusting

Now we'll dial in the fit before the permanent install.

Test Fitting (Again!): Place the Rocket Bunny kit pieces back on the car and check the fitment. Make any necessary adjustments by trimming or grinding.
Addressing Gaps: Gaps are inevitable with aftermarket body kits. Use body filler or shims to fill any significant gaps. Smaller gaps can be addressed with seam sealer.
Bracket Fabrication (If Necessary): Some Rocket Bunny kits may require custom brackets to ensure proper fitment. If this is the case, use steel or aluminum to fabricate brackets that attach to existing mounting points on the car. Welding skills are essential here.
Wheel Clearance Check: With the kit temporarily installed, check for wheel clearance. Ensure that the tires do not rub against the fenders, especially during suspension compression. You may need to roll or pull your fenders further to achieve adequate clearance.

Step 4: Final Preparation and Painting

Getting ready for the final touches.

Surface Preparation: Thoroughly clean the Rocket Bunny kit pieces with a degreaser and wax and grease remover. This ensures proper adhesion of the primer and paint.
Priming: Apply several coats of automotive primer to the kit pieces, allowing each coat to dry completely before applying the next. Sand the primer smooth with fine-grit sandpaper (400 grit).
Painting: Apply several coats of automotive paint to the kit pieces, allowing each coat to dry completely before applying the next. Consult with a paint professional for the best application techniques and drying times.
Clear Coat: Apply several coats of automotive clear coat to the kit pieces, allowing each coat to dry completely before applying the next. This will protect the paint and give it a glossy finish.

Step 5: Installation and Finishing

The final stretch! Time to put it all together.

Panel Bonding/Riveting: Apply a bead of body panel adhesive to the mating surfaces of the Rocket Bunny kit and the car's body. Then, use rivets or self-tapping screws to secure the kit in place. Follow the manufacturer's instructions for rivet spacing. Alternatively, the use of strong panel bonding adhesive in conjunction with a few well-placed rivets or screws is a popular method.
Seam Sealer: Apply seam sealer to any gaps between the Rocket Bunny kit and the car's body. This will prevent water and debris from entering and causing corrosion.
Reassembly: Reinstall the bumpers, side skirts, inner fender liners, and any other body panels that you removed during disassembly.
Final Touches: Clean the car thoroughly and inspect the installation for any imperfections. Touch up any areas as needed.
Wheel Alignment: After installing the Rocket Bunny kit, it is highly recommended to get a professional wheel alignment. This will ensure that your car handles properly and that your tires wear evenly.

Common Pitfalls and Troubleshooting

Poor Fitment: This is the most common issue. Patience and careful trimming are key. Don't be afraid to use shims or body filler to address gaps.
Rust: Exposed metal will rust if not properly protected. Use rust-preventative primer on all cut edges.
Panel Gaps: Seam sealer is your friend! Apply it liberally to any gaps to prevent water intrusion.
Tire Rub: Ensure adequate wheel clearance. Rolling or pulling fenders may be necessary. Consider adjusting ride height or using different wheel offsets.
Improper Riveting: Use the correct rivets and a heavy-duty rivet gun. Over-tightening can damage the fiberglass.

Installing a Rocket Bunny V2 Boss Kit is a challenging but rewarding project. With careful planning, proper preparation, and a willingness to learn, you can transform your car into a true head-turner. Remember to prioritize safety, take your time, and don't be afraid to ask for help if you get stuck. Good luck, and happy modding!