he final chapter in Roadster Shop’s 1965 Corvette build focuses on a detail that can separate a good car from an exceptional one: the bumpers. While bumpers are frequently treated as bolt-on components, this project demanded far more. To achieve the tight, integrated look expected at this level, both the front and rear bumpers were extensively reshaped to sit closer to the body and follow its contours with precision.

Work began on the front bumpers, focusing on the downward-pointing strakes beneath the horizontal sections. The team decided that lengthening the strakes would allow them to tie in with the body more smoothly. The strakes were carefully cut away from the main bumper to make the rework more manageable.

To ensure consistency, a pattern was taken from an original strake to capture the factory character. That pattern was then revised to establish the new length and refined contour. Using this updated pattern, new blanks were cut from cold-rolled steel sheet. The blanks were notched along the outer edges, allowing the metal to be shaped into the required contours without introducing unwanted distortion.

After the rough shaping was complete, each notch was carefully filled by TIG welding. This produced welds suitable for high-level metal finishing. The blanks were then methodically tweaked until the contours flowed smoothly and matched perfectly from side to side. To maintain alignment during final adjustments, the blanks were tack-welded to a heavy workbench, holding them rigidly while the seams joining each pair were finish-welded, then metal-finished to perfection.

Once complete, the strakes were re-welded to the horizontal bumper sections. Careful attention was paid to alignment, fit, and overall proportion before the assemblies were smoothed to perfection.

A small, peaked spreader bar was then fabricated to fit between the bumper segments. Pockets were added to each bumper half to positively locate the ends of the spreader bar, ensuring the precise alignment would be retained.

The rear bumpers went through a similar transformation, though they had additional challenges due to their closer interaction with the fiberglass body. Achieving a snug, glove-like fit required careful tweaking of the fiberglass panels before the final bumper adjustments could be made. Once the body contours were shaved down and refined, a metal extension was added to the bottom edge of each rear bumper to close the gap against the body. These extensions were shaped, welded, and metal-finished to become completely integrated with the design.

As with all high-end metalwork, the process involved numerous rounds of fitting, removal, and adjustment. Each change was subtle, but together they resulted in consistent gaps, clean lines, and precise alignment from every angle. With the final contours established, the bumpers were given their finishing touches in preparation for chrome plating, where flawless surfaces are essential.

The result is a set of bumpers that are consistent with the quality of the entire build. Each component looks purposeful, refined, and fully integrated with the body. It’s a fitting conclusion to a project defined by attention to detail, and a reminder that excellence is often found in the parts some builders overlook.