Ford Fusion Body Kit – Achieve A Custom Performance Look And Improved
Upgrading your vehicle with a high-quality body kit is the most effective way to transition from a standard commuter to a head-turning performance machine. This guide provides the technical insights and step-by-step instructions needed to select, prep, and install your components for a seamless, factory-level finish.
Most car enthusiasts agree that the second-generation Fusion is one of the best-looking sedans Ford ever produced. However, if you want to truly separate your ride from the thousands of others on the road, a Ford Fusion body kit is the ultimate solution. I promise that by following this roadmap, you will understand how to navigate the complexities of fitment, materials, and installation safety.
In the following sections, we will preview the essential tools you will need and the specific differences between material types. We will also cover the “pro” secrets that prevent common issues like sagging or paint peeling. Let’s dive into the world of custom aerodynamics and give your Fusion the aggressive stance it deserves.
Choosing the Right Ford Fusion body kit for Your Generation
Before you click “buy” on that aggressive new front splitter, you must identify your specific model year and trim level. The Ford Fusion underwent a significant redesign in 2013, moving from the boxier first-generation style to the sleek, Aston Martin-inspired second generation. A Ford Fusion body kit designed for a 2012 model will not fit a 2013 or newer chassis due to completely different mounting points.
Within the second generation (2013-2020), there was also a “facelift” in 2017. This refresh changed the shape of the fog light bezels and the lower grille area. If you own a Sport or Titanium trim, your bumper covers might have different sensors or cooling vents compared to the base S or SE trims. Always verify that the kit specifically mentions your year and trim to avoid expensive return shipping costs.
You also need to decide on the “completeness” of the kit. Some owners prefer a full replacement kit, which involves swapping out the entire front and rear bumper covers. Others opt for “lip kits,” which are add-on components that bolt onto your existing factory bumpers. Lip kits are generally more DIY-friendly and affordable for those just starting their modification journey.
Material Science: Selecting Between Polyurethane, ABS, and Carbon Fiber
The material of your components dictates how long they will last and how much abuse they can take from daily driving. Polyurethane is the gold standard for daily drivers because it is incredibly flexible. If you accidentally scrape a curb or a steep driveway, polyurethane will usually flex and pop back into shape rather than cracking.
ABS plastic is another popular choice, often used by Original Equipment Manufacturers (OEMs). It is more rigid than polyurethane, which allows it to hold complex shapes better, but it is more prone to snapping if subjected to a heavy impact. ABS is generally easier to paint-match because it holds its shape perfectly during the curing process in a paint booth.
For those focused on weight reduction and high-end aesthetics, carbon fiber is the premium option. It offers an unmatched strength-to-weight ratio and a distinct weave pattern that many enthusiasts leave unpainted. However, carbon fiber is brittle; a hard strike from road debris can cause it to shatter, making it a “high-risk, high-reward” choice for street cars.
Fiberglass: The Budget-Friendly Alternative
Fiberglass (FRP) is often the most affordable material, but it requires the most work. It is very rigid and does not flex, meaning it will crack easily. Furthermore, fiberglass parts often require significant sanding and filling to achieve a smooth finish, as the molds are rarely perfect from the factory.
The Essential DIY Toolkit for Exterior Modifications
Installing a Ford Fusion body kit requires more than just a screwdriver. To do the job safely and correctly, you need a stable workspace and the right hardware. Start by ensuring you have a high-quality hydraulic floor jack and a set of jack stands. Never work under a vehicle supported only by a jack.
You will also need a power drill with a set of sharp cobalt drill bits designed for plastic and thin metal. Most kits require you to drill “pilot holes” into the underside of your factory bumpers. Having a rivet gun or a collection of stainless steel self-tapping screws is vital for ensuring the parts stay attached at highway speeds.
Finally, do not underestimate the power of surface preparation. Stock up on high-strength 3M VHB tape and an adhesion promoter. While screws provide mechanical strength, the double-sided tape ensures there are no visible gaps between the kit and the car body. A heat gun is also helpful for warming up the tape to ensure maximum stickiness during installation.
Pre-Installation Checklist: Why Test-Fitting is Non-Negotiable
One of the biggest mistakes a DIYer can make is painting a part before checking the fit. Use painter’s tape to mock up the components on your Fusion. Check the alignment near the wheel wells and ensure the lines of the kit flow naturally with the body of the car. If the part is warped, you may need to use a heat gun to gently reshape it.
Check for “clashing” with other components. For example, does your new front lip block the airflow to the intercooler (if you have the 2.0L EcoBoost)? Does the rear diffuser interfere with your exhaust tips? Identifying these issues early allows you to trim the plastic or adjust the mounting points before any permanent changes are made.
Once you are satisfied with the fit, mark your drill holes with a silver sharpie or a center punch. This ensures that when you move to the final installation, everything lines up perfectly. This “dry run” phase is what separates a professional-looking build from a sloppy, rushed job.
Step-By-Step Installation: Front Splitters, Side Skirts, and Rear Diffusers
- Clean the Surfaces: Use isopropyl alcohol to remove all wax, grease, and road grime from the areas where the kit will touch the car. This is crucial for the 3M tape to bond effectively.
- Apply Adhesion Promoter: Wipe the promoter onto the car’s body and the back of the body kit. This chemical bond makes the tape nearly impossible to peel off once it sets.
- Apply the Tape: Place the 3M VHB tape along the edges of the Ford Fusion body kit. Peel back only about two inches of the red backing on each end, leaving “tails” that stick out. This allows you to position the part before fully committing to the adhesive bond.
- Position and Secure: Have a friend help you hold the part in place. Once aligned, pull the “tails” of the tape backing to expose the rest of the adhesive. Press firmly along the entire edge for at least 60 seconds.
- Mechanical Fasteners: Drill your pilot holes through the pre-marked spots. Insert your screws or rivets. I recommend using fender washers on the inside of the bumper to distribute the load and prevent the screws from pulling through the plastic.
Repeat this process for the side skirts. Side skirts can be tricky because they are long and prone to sagging in the middle. Ensure you use at least one screw every 12 inches to maintain a straight line along the rocker panels.
Advanced Finishing: Painting and Protecting Your Investment
If your kit arrived in a raw “unpainted” finish, you have two choices: paint-matching or contrast-painting. Paint-matching makes the car look like it came from the factory with the kit. Contrast-painting (usually in gloss black or carbon flash) highlights the modifications and gives the car a more aggressive, aftermarket look.
Before painting, sand the parts with 400-grit sandpaper to create a “tooth” for the primer. Use a high-build primer to fill in any tiny imperfections in the mold. When applying the color coat, use light, even passes to avoid drips. Always finish with a 2K clear coat, which contains a hardener that protects the paint from UV rays and gasoline spills.
After the paint has cured for at least 48 hours, consider applying a ceramic coating or a paint protection film (PPF). Since body kits sit low to the ground, they are constantly bombarded by rocks and road salt. A protective layer will keep your new modifications looking fresh for years rather than months.
Maintenance and Long-Term Care for Exterior Mods
A modified car requires a different maintenance mindset. You must now be acutely aware of “approach angles.” When entering a parking lot with a steep incline, take it at an angle rather than head-on. This prevents the front splitter from “plowing” into the pavement and cracking.
Check your hardware regularly. The vibrations from driving can occasionally loosen the screws or rivets holding your kit in place. Every time you change your oil, take five minutes to tug on the edges of your Ford Fusion body kit to ensure everything is still tight. If you notice a gap forming, re-apply a fresh strip of 3M tape immediately.
Avoid automated “brush” car washes. The heavy bristles can catch on the edges of your splitters or diffusers and tear them off. Stick to touchless washes or, ideally, hand-washing with a two-bucket method. This prevents scratches on your custom paint and ensures your aerodynamic components stay exactly where they belong.
Frequently Asked Questions About Ford Fusion Body Kits
Does a body kit improve my car’s gas mileage?
Generally, no. While some kits are designed for aerodynamics, most aftermarket kits for the Fusion are styled for aesthetics. The added weight and increased frontal surface area might actually cause a very slight decrease in fuel economy, though it is usually negligible for daily driving.
Will installing a kit void my Ford factory warranty?
In the United States, the Magnuson-Moss Warranty Act protects you. A body kit will only void the warranty on parts it directly affects. For example, it won’t void your engine warranty, but it might void the warranty on your bumper paint or proximity sensors if they were modified during installation.
Can I install a body kit alone, or do I need help?
While you can do the prep work alone, I highly recommend having a second person for the actual mounting. Holding a six-foot-long side skirt perfectly level while trying to start a screw is nearly impossible without help. Having an extra set of hands ensures perfect alignment and prevents the parts from falling and getting scratched.
What is the best way to fix a crack in a polyurethane kit?
Polyurethane can be repaired using a specialized “plastic welding” kit or a flexible epoxy designed for bumper repair. Unlike fiberglass, you cannot use standard body filler because it will crack when the polyurethane flexes. Always use flexible additives in your primer and paint when repairing these components.
Final Thoughts on Customizing Your Fusion
Transforming your car with a Ford Fusion body kit is a rewarding project that combines technical skill with creative vision. By choosing the right materials, such as durable polyurethane, and taking the time to perform a proper test-fit, you ensure that your modifications enhance both the beauty and the value of your vehicle.
Remember that safety is the most important part of any DIY project. Always use jack stands, wear eye protection when drilling, and double-check your fasteners. Once the work is done, you’ll have a one-of-a-kind Ford Fusion that reflects your personal style and stands out in any crowd. Stay safe, take your time, and enjoy the new look of your ride!
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