Update - Mods - Exterior

4.6is Front Lip: As you're aware, there aren't a lot of options for facelift owners to add a lower front lip. You can either go the eBay fiberglass replica route, buy an entire front 4.8is front bar new, or be lucky enough to find a 4.8is front bumper at a wrecker. Or, with a bit of patience, you can fit a 4.6is front lip. I managed to score this one from a wrecker at the same time I bought the 4.6is rear bar. It cost me less than an unpainted eBay replica so I figured it was worth a shot.

The 4.6is front lip does require some trimming to fit. There are small tabs all along the rearward edge that slot into the grey plastic bumper section on the 4.6is. You can either cut these slots into your bar, or cut them off the lip. I chose to do the latter. A dremel with a cut off wheel makes light work of this. Then you need to enlarge all the U-shaped slots in the top edge of the lip where it meets the air dam on the standard bumper. This takes a fair bit of trial and error work, trim a bit, offer it up to the car, trim a bit more etc.

To fix the lower lip to the car I used Sikaflex Fix-AU, basically a flexible automotive adhesive that can withstand vibrations. Cure time is about 12 hours so I held it in place with quik-clamps. The quick clamps also help get a good fit around the corners as there will be a slight gap (the 4.6is lip has squarer corners than the facelift front bumper).

Very happy with the outcome.

Pics below:

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2005 3.0d Sport - Sapphire Black
Engine : Bluefin Superchip Tune,
Wheels & Sus: Style 168s (10.5s all round), H&R RDA Spacers, Bilstein B12, Eibach 40mm drop, Whiteline RSB
Exterior: Le Mans flares, 4.6is kit F&R
Interior: Dynavin N6, Blackvue DR650 dash cams

My Build Thread: http://www.xoutpost.com/bmw-sav-foru...run-sheet.html