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Mold an Aerogear body kit to a Cougar

The hot new Millennium kit gives the cat-like coupe a "purrfect" new look.
From the June, 2009 issue of Lowrider Edge
By Dick DeLoach
Illustrators: Dick DeLoach
Mercury Cougar Passengers Side View
1. With the Aerogear Millennium... 
   
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Mercury Cougar Passengers Side View
1. With the Aerogear Millennium body kit, NSX side scoops and 19-inch Quantum Tek S-13 alloys this is one of the coolest Cougars we've seen.
Mercury Cougar Front Drivers Side View
2.
Mercury Cougar Rear Drivers Side View
2. & 3. The first thing to... 
   
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Mercury Cougar Rear Drivers Side View
2. & 3. The first thing to do is to lay all of the "baby blue" gel-coated parts out to make sure that the kit is complete.
0305Lre Aerogear04 Z
4. Every Aerogear part has... 
   
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0305Lre Aerogear04 Z
4. Every Aerogear part has an official ID tag with individual serial numbers.
Mercury Cougar Rear View
5. The new Aerogear rear bumper... 
   
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Mercury Cougar Rear View
5. The new Aerogear rear bumper cover will completely replace the factory cover.
Mercury Cougar Rear View
6. Then, Abel began by jacking... 
   
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Mercury Cougar Rear View
6. Then, Abel began by jacking up the rear of the car, removing the tires/wheels, taillight assemblies and the rear bumper cover. The Aerogear bumper cover was then attached using the stock hardware.
Mercury Cougar Front Drivers Side Quarter
7.
0305Lre Aerogear08 Z
7. & 8. Each part was test... 
   
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0305Lre Aerogear08 Z
7. & 8. Each part was test fitted then, for added strength, attached with special self-tapping screws (instead of double-sided tape) at the proper points as shown.
Mercury Cougar Drivers Side View
9. Next, after removing the... 
   
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Mercury Cougar Drivers Side View
9. Next, after removing the headlight assemblies, the front bumper cover was removed and the Aerogear cover installed. The installation could end at this point if you wanted the "riveted" race look.
0305Lre Aerogear10 Z
10. Jimmy wanted a more custom... 
   
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0305Lre Aerogear10 Z
10. Jimmy wanted a more custom look, so Abel ground down the screw heads and filled them with Kitty Hair fiberglass. A light coating of plastic body filler would be added later.
0305Lre Aerogear11 Z
11. Even the side skirt screws... 
   
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0305Lre Aerogear11 Z
11. Even the side skirt screws were ground down along the door sills.
0305Lre Aerogear12 Z
12. Here are the supplies... 
   
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0305Lre Aerogear12 Z
12. Here are the supplies that Abel will use for the filling and painting.
0305Lre Aerogear13 Z
13. After applying the plastic... 
   
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0305Lre Aerogear13 Z
13. After applying the plastic body filler everything is wet-sanded with fine-grit sandpaper.
0305Lre Aerogear14 Z
14. The body is ready to be... 
   
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0305Lre Aerogear14 Z
14. The body is ready to be primered and painted.
Mercury Cougar Rear View
15. Jimmy decided to have... 
   
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Mercury Cougar Rear View
15. Jimmy decided to have Abel shave the Mercury emblem off of the trunk lid.
Mercury Cougar Rear Passengers Side Quarter
16. After seeing how the kit... 
   
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Mercury Cougar Rear Passengers Side Quarter
16. After seeing how the kit looked, Jimmy decided to have Abel go all the way and "mold" it in.
0305Lre Aerogear17 Z
17. Even the doorjambs and... 
   
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0305Lre Aerogear17 Z
17. Even the doorjambs and side skirts were molded in.
Mercury Cougar Front View
18. An Aerogear Series 1 Predator... 
   
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Mercury Cougar Front View
18. An Aerogear Series 1 Predator hood was also installed.
0305Lre Aerogear19 Z
19. NSX-style side scoops... 
   
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0305Lre Aerogear19 Z
19. NSX-style side scoops would be molded in each side.
Mercury Cougar Front Drivers Side View
20. The finished transformation... 
   
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Mercury Cougar Front Drivers Side View
20. The finished transformation makes the Cougar look more sleek and stylish.
Mercury Cougar Hood View
21. The new hood is lightweight,... 
   
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Mercury Cougar Hood View
21. The new hood is lightweight, stylish and provides increased air flow to the engine.
Mercury Cougar Rear Bottom Quarter View
22. The large ducts in each... 
   
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Mercury Cougar Rear Bottom Quarter View
22. The large ducts in each side of the rear bumper cover provide improved air flow for the rear tires and brakes.
Mercury Cougar Wheel
23.
Quantum Tek Alloys
12850 Moore St., Dept. LRE
Cerritos
CA  90703
www.qtalloys.com
Aerogear
249 W. Jackson St., Dept. LRE
Hayward
CA  94544
www.aerogear.net
Best Auto Body
10638 Unit "F" Painter Ave., Dept. LRE
Santa Fe Springs
CA  90670
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