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1st gen DIY bumper write up

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Old 12-20-2013, 03:48 PM   #1
4banger4x4 [OP] 4banger4x4 is online now
Probably should'nt have done that.
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1st gen DIY bumper write up

Im gonna be updating this as i go being that this might take a few days and i want to keep everything in order and be able to provide as much detail as possible.

Sorry this is incomplete but i forgot to take pics after a certain point.

what i will tell you is this is not for the faint of heart and i was doing it 100% by myself and trying to get everything just right while its on the truck is extremely hard by yourself, i ended up having to cut some of the side pieces down because i couldnt get the angles right on the wing plates.

total time from sand blasting to first coat of paint was prob 10-12 hours of work

Parts and items needed
-1st gen DIY bumper from Relentless fab
-17mm socket and extension
-M12x1.25 bolts x4
-1/2"x20 bolts and nuts x2 (only for 98-00)
-Reciprocating Saw
-8"-12" saw blades


This pile of steel showed up at my house and the fun begins.


The first thing I did was sand blasted everything. Its not necessary but I did it beacuse I have access to it and it will make prep before painting easier.
Before:

After:


The next thing I did was weld the fog lights up, its recommend to do it as one of the last things but I wanted to do it while it was laying on the bench.

Im gonna try and tig as much as i can on this bumper :]


Next on the list was to prep my frame, keep in mind i have a 98 so i have to cut my frame as well as my skid plate mounts and weld in new mounting plates.

Took the frame caps off with a 17mm socket and cut the skid plate mount off. be extremely carefully cutting off the skid plate bracket if you are using a reciprocating saw, you dont wanna punch a hole in your radiator. You can see a small gap between the frame and the radiator support, that is where i aimed the end of the saw blade. I used an 8" blade for this but thats all i had and it worked perfect.


I also cut the front of these things off just so it was easier to cut the frame.


Measure 3" back from the front and mark your line and start cutting. I used the 8" blade again but i think a 12" would have made it a lot easier to get the saw in there


Then i welded the 1/2"x20 nuts on to the back of the frame plates (98-00 Only)
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Old 12-20-2013, 03:56 PM   #2
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Mainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shedMainmoe02 is one of the sharper tools in the shed
 
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Very interested to see how this works. I'll be doing the same next week hopefully
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Old 12-20-2013, 04:36 PM   #3
4banger4x4 [OP] 4banger4x4 is online now
Probably should'nt have done that.
4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed
 
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Originally Posted by Mainmoe02 View Post
Very interested to see how this works. I'll be doing the same next week hopefully
hopefully i can atleast get it all tacked up tomorrow at the shop.
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Old 12-20-2013, 04:40 PM   #4
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Looking good. I will be making a thread similar to this one when I get ready to weld mine up!
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Old 12-20-2013, 04:41 PM   #5
4banger4x4 [OP] 4banger4x4 is online now
Probably should'nt have done that.
4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed
 
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Originally Posted by BamaToy1997 View Post
Looking good. I will be making a thread similar to this one when I get ready to weld mine up!
good cause i have a feeling im going to forget some stuff
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Old 12-20-2013, 04:42 PM   #6
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Old 12-20-2013, 06:27 PM   #7
cmj cmj is offline
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Sub'd. I will be starting mine as soon as the frame end caps show up
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Old 12-20-2013, 06:33 PM   #8
4banger4x4 [OP] 4banger4x4 is online now
Probably should'nt have done that.
4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed4banger4x4 is one of the sharper tools in the shed
 
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Quote:
Originally Posted by cmj View Post
Sub'd. I will be starting mine as soon as the frame end caps show up
youre gonna have to grind them down to make them fit and the holes in the plates are not centered so youre gonna have to make sure they are facing the right way so your bumper is centered on your truck
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Old 12-20-2013, 06:41 PM   #9
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Cool. Thanks for the heads up
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