2nd gen bumper build

Update: I've decided to post a picture of each finished build I make in this first post, I will try to keep this updated as I finish more projects.

Front bumper:



High clearance rear bumper:



In progress watch for near daily updates.

Hi everybody decided to try building a plate bumper for my 2008. I'll try to post up pics as I make progress. This is my first bumper build so it will be a lot of trial and error feel free to leave feed back constructive criticism is welcome. I appreciate any input because if this doesn't turn out good I'll have to build another one.
I also have a tube bender so once the base is complete I'll try making some hoops for on top.




First I made a cardboard template of the center of the bumper.

Once I was happy with the basic shape of the center piece I transferred the measurements on to 3/16" plate steel.




I've looked all over for bumpers that have skids to protect a DB to no avail do I'll try to incorporate that into this build.
I wrote all of my dimensions on incase any body cares to copy my design I looked all over the internet and couldn't find any free plans so take it for what it is. I will try to include all my dimensions as I go along, hopefully it will help somebody out in the future as well as help with any tips people have to make this thing turn out.






Unfortunately I don't have a plasma cutter at home yet so I tried cutting it with a sawsall first but I couldn't get the lines as straight as I wanted. If I didn't think it would warp I would have preferred to torch it but I ended up resorting to my 4 1/2 Milwaukee grinder with cutoff discs.





Once I had the basic shape cut out I began to cut about half the thickness of the plate where I plan on bending it to shape. Yes I could cut it completely apart and weld it but hopefully this will cut down on some of the welding. Less welding = less heat distortion. Once scored enough I clamped it to another piece of steel along the seam to try and bend it as cleanly as possible.


Well that's where I'm at for the night hopefully I'll have some time to work on it more in the morning.

 

Sounds like you're off to a good start! What kind of pipe bender do you have? I went the harbor freight route and haven't had a whole lot of time to play with it but I haven't had very good results yet.

 

Thanks for your interest. I have a jd2 model 32 with 1 1/4" and 1 3/4" tubing dies

 

Here's a quick pic of my bender.... Don't mind the messy garage I just moved.

 

Looks like your on the right track, I'm subbed.

 

Sweet. Is a thread around for bumper builds? Would be a great idea.


Wish I had access to a bender would have made mine much easier then to weld and smooth all the edges on the front

 

Sorry about the lack of posts but I've only had a few minutes here and there to work on it this week.


So I decided it would be easier to drill all the mounting holes before I got everything bent up. Here is a mock up to see if everything was lining up.


Then I brought it over to my redneck 2x4 break to assist in bending.



This is we're it sits as of right now I will be working on it some more today.

 

It's been awhile but I've finally had time to work on this done more. Started by redoing the top plate. The first one didn't follow the curve of the grill very well.Next
I made the pieces for the top of the wings along with a small kicked up angle at the edges of the grill to follow the body lines. This wad the hardest part of the whole build so far and really makes me want a plasma cutter at home.Next I made a small steel wedge on each side of the center section (sorry no pic of the work in progress but you can see it in the next pic) along with cardboard templates of the bottom portion of the wings. Followed by steel which is tacked together and how it sits currently. It's not perfect but I'm running out of time and had to whip something together before the snow flies. Did I mention this entire thing was cut with a 4" grinder. Plasma cutter is on my list now for sure lol.

 

Very nice. I like seeing work done with basic tools, it takes alot of patience. Good job!

 

Thanks I still have a lot to do on this project but it's been hard to find the time to work on it. Working with basic tools really makes you appreciate the luxuries such as a plasma cutter a lot more. The truth is if you have enough time and patients you can accomplish quite a bit with just the basics. It just takes a lot longer. This last update was all done in about three and a half hours very early this morning so I guess that's not too bad as far as time goes.

 

Looking awesome!!!

 

Made progress on the bumper build today. It is now mostly all welded up and ground smooth.Also removed the ugly factory tow hook bar, added gussets to the base, and another triangle piece to the bottom of each wing. Now I need to figure out retrieval points and skid plates along with some led light bars. I haven't decided if I'm going to put hoops on it for sure or not. Then it will be time for some sort of finish that I'm also undecided about right now.

 

Updates?!?

 

Sorry about the lack of updates time has been very hard to come by lately... But here is a small peak at what I've been up to when I have a few minutes here or there. I've also made d-ring mounts but they are still in progress then it's just a few reinforcements a skid and paint. Sorry don't have any pics with the light bar mounted but you get the idea. The expanded is aluminum an bolts on with threaded rod. I will be painting the expanded red and probably rhino liner or line-x the rest. Going slower then I planned but it's okay I'm not on a set schedule.

 

Looks good! I made my front bumper as well ( well I should add that the main frame of it is an Aries?? Brushguard that I cut apart and added all my own lower pieces) but did it all with an angle grinder and redneck bending same as you. Cost me nothing to do and I like the look. Nothing better than building something yourself and saving the money!

 

Here's a pic of the D-ring shackle mounts but there not finished yet

 

Is that a couple old box springs from someones bedroom?I have never seen a welding table of that kind.

 

Lol yea they were in my way and I plan on throwing them away so they worked to keep my work at waist height. I don't like working off the floor. And I guess I'm a little bit of a redneck haha.

 

Had a chance to bolt it together and put it on the truck this morning not too much progress I just wanted to see it with the light bar and expanded in place. Kind of a pain trying to work on anything in this weather and, I need to get a 7/8 drill bit for the shackle mounts before I can weld those on and then figure something out for a skid plate. But until next week here's where it is at. Also trying to decide weather or not to round the edges on the shackle mounts. What do you guys think? They are perfectly identical to each other side to side right now just worried if I round them they may not be.