I believe the stock S197 rear bumper cover is made of thermoplastic (TPO), which is usually a black plastic material.

I find that this crap is easily damaged. An object in my garage fell on my rear bumper cover and took a huge chunk out of the cover. I've had lots of different things hit my Crown Vic's urethane bumper covers and not even flinch (including a Cadillac STS) let alone crack.

Just today, I went to grab a garden hose to clean off a high speed bird poop drop (75 mph on the highway, got hit square on the hood) and the hose tapped my rear bumper cover in the corner and left 4 scratches, one of which went straight down to the black plastic material. This is the absolutely sh*ttiest bumper cover material / paint I have seen.

Where can we buy a urethane rear bumper cover for the S197 GT or perhaps something made of more durable material? I wanted to get rid of the rear cover anyhow because of the big gash.

 

I've seen ads for take-offs in the 5.0 Mustang mag, but I don't have one at work to look in. If you're lucky, you might even get one the same color as your car, saving you the cost of painting it. I believe Saleen sells all their take-off parts too, unless they're moving them through another reseller now. You might contact them.

 

He wants someone to make the exact same covers as stock just in a different material

 

Kevin is right. The TPO garbage they used for the stock bumper cover is as weak as wax. The urethane bumpers Ford used since the early 80s can take a severe beating without any problems (yellow plastic material).

 

The only issue with urethane is that it can get wavy over time. The thermoplastic will maintain it's shape better. Just be more careful!