Many hours and a can of Plasti-Dip later, I have given my car the spirit of evolution (thats what I call this project lol). Seeing as I now have knowledge on the subject I might as well write up a tutorial of some sort for everyone else. So here it goes!
This is a very easy modification to complete, it can be a bit time consuming if you dropped a plastic clip into the engine and still have not found it. If you plan to black out the front end of your Lancer so it looks similar to the EVO, listen up!
Step 1: Remove the license plate, self explanatory. Then unscrew the two screws at the air intake, very simple!
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(IMG:http://img9.imageshack.us/img9/2691/dsc02653w.th.jpg)
Once complete, there are four black circle clips holding down the big black piece where the air intake rests on. I dont know what you could call it so bare with me! Take a flathead screwdriver and pop up the disk on each one, then you can actually pull them out.
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(IMG:http://img23.imageshack.us/img23/3606/dsc02654b.th.jpg)
[WARNING: Don't let any of those clips shoot up and disappear into the engine, I spent 2 hours looking for one and jacked up the car and used a mirror and everything. Still cant find it, so I have to risk it melting to something.] Once you have the 4 clips out, the black piece should come off easy, just pull it up and away!
Step 2: Stop looking for the black clip in the engine compartment, you wont find it. Instead, get a philips screw driver and make it short, we need to remove the grill. If you remove the grill it makes life sooooooo much easier. You need a short screwdriver or a ratcheting screw driver because there is not a lot of room to unscrew the grill. Luckily its very easy, there should be 8 screws total, 4 of which unscrew the grill itself. The other 4 smaller screws remove the black criss-cross pattern and Mitsubishi logo from the chrome portion of the grille. There are also 4 clips, they brake easy, so be gentle when you pull the grille out. If you have a wife or a girlfriend, this concept should be no stranger to you lol. You can tape it like I did or spray the entire thing, it does not matter.
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(IMG:http://img5.imageshack.us/img5/4574/dsc02656syb.th.jpg)
Step 3: This is one of the parts that sucks. We don't want to get the rest of the car dirty so we need to tape and paper off everything. If I catch you using scotch tape or duct tape I will destroy you so stick to the blue painters tape, it comes off easy and doesn't leave residue on the paint. Tape off everything you don't want black. Feel free to follow my example in the picture. The paper works great for covering big distances.
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(IMG:http://img38.imageshack.us/img38/7134/dsc02657p.th.jpg)
Now I went a step further and blacked out the bottom fins and lip of the bumper. See it in this next pic, taping this off sucked cause its hard to get it even, and to decide how exactly you want it. I probably could have gotten creative and made something to make them even but I didn't, turned out ok though!
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(IMG:http://img38.imageshack.us/img38/737/dsc02658ona.th.jpg)
Step 4: Hopefully you taped up everything nice and well, now we get dirty and start the spraying!! Please, DO THIS IN A NON-WINDY, WELL VENTILATED AREA. The wind will mess everything up. I had no wind for the first 4 coats, then it came at the last minute and made it difficult. Anyway, enough about me, lets talk about you. You will need to spray this kinda like a typewriter, start at the top and go all the way across at an even pace. Start spraying on the tape first, then spray across and stop spraying on the tape at the other end. Move down a bit, and repeat. You DON'T WANT OVER SPRAY. Whats that? Its when you overlap too much with the layer above that you just sprayed. Overlap about half an inch. So look at this pic and try to figure it out yourself.
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(IMG:http://img35.imageshack.us/img35/4305/dsc02661vkw.th.jpg)
"How many layers Duffmaster? Please tell us the secret!" F U, go away! Ok fine, I did about 6 layers, but you could probably get away with 4 if you wanted too. I might have even gone 8, there gets a point where it looks the same even if you keep adding onto it. I waited 15 minutes between each coat, it is still somewhat smooth and doesn't have that rubber look. Because I did the lower part of the grill and the fins, it took me 1 can and 1/8th of another can. So if you do just the bar and grille, only one can is needed. Once done I let it all dry for 30 minutes.
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(IMG:http://img43.imageshack.us/img43/2926/dsc02662snr.th.jpg)
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(IMG:http://img9.imageshack.us/img9/6024/dsc02663p.th.jpg)
Step 5: This part sucks as well. Time to remove the tape and paper!! Get a razor blade and some popcorn with a nice cold beer. If you want to do it right, it will take you some time. About 20 minutes. Its simple but time consuming, just remove the paper and tape on the outside first, cut as much of it off as you can without getting to the black part. Cut off even more than this picture shows.
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(IMG:http://img190.imageshack.us/img190/5075/dsc02664q.th.jpg)
Now time to sweat bullets as you try to peel off the tape without peeling the Plasti-Dip with it. Use the razor to cut it as you peel, get close, you don't want to lift up the plasti-dip. If you do, don't worry too much, a little bit is ok but don't make it a habit. GO SLOW, thats why I had you get popcorn and a good beer.
Step 6: Step back, cry a bit at how beautiful it looks from far away, then cry some more at how horrible the edges look close up. Don't worry, the edges look great unless your about a foot from it. If you need too, you can get a small brush, spray the plasti-dip in the cap, and brush it on the parts you need to. You will need to apply a ton of coats though. But from a distance it looks damn good! And everything else, except the edges, look great from any distance!
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(IMG:http://img7.imageshack.us/img7/6097/dsc02669o.th.jpg)
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(IMG:http://img200.imageshack.us/img200/5873/dsc02671z.th.jpg)
Step 7: Cry just a bit more because your a poser who doesn't actually have an EVO. But take comfort in knowing that most of us are the same way. Counseling services are a short phone call away! (IMG:
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