Well, this topic is pretty much hijacked. I wish there was more information about the molding process being discussed here, such as what the thread starter was requesting.
So, to get it back on track:
Shawn, I'm pretty serious about doing this. I think I'm going to end up buying a urethane welder and this how-to book and try to do it myself. The way I figure it, its probably going to cost $200 max for the equipment and tools and materials (minus bumper costs), which would save me $400 easily. If I buy this equipment, you're welcome to use it for your project.
Beyondloaded PM'd me and it sounds pretty straightforward: cut, weld, sand down bumpiness from the weld, fill in shallow spots or holes with duramix, prime, paint, win. (I'm going to have a bodyshop paint it, but I think everything up to the primer part should be do-able). I dunno how easy it would be for your rear bumper thing but that's the process.
