Bored Clerk's Rear Bumper Build

Looking good man been. Watching

 

Thanks! I'll be back on it tonight. I want to wrap up the other spring pin mount and drill the holes for the license plate. Still going to be pretty hot but much better than this last weekend!

 

Finished up a little item tonight. Well, it's finished but not tested. It may prove to be an issue in the future but it's easy change should it be necessary.

I figured out my rubber bumper issue! If you recall, I've been stressing about the 'bumper' that will be in compression when the swing out is being held by the giant clamps. I ordered urethane die springs...high durometer, high spring rate. So far I really like them.

Here's how I attached them:


Die spring. They come in a lot of different sizes, rates, and working loads. These seem perfect and the size is exactly right. Now, how to attach them... I already have a 5/16" hole drilled and tapped that I can use...so I used it.


Here's the kit: 5/16" bolt, 1/4" washer, 3/8" heater hose, die spring.


Lube it up! The heater hose is a press fit into the center of the die spring. So, hitting it with some lube lets it slide right in.


See!


Now, drop the bolt and washer into place.


Now you see why I used a 1/4" washer. I used a 1/4", grade 8, cut washer...it was the perfect size. It still fit over the 5/16" bolt but the OD fit exactly into the ID of the die spring.


You only push the rubber tubing in far enough to be flush with the bottom of the die spring. Not super critics as the bolt will pull it flush. The most critical part is cutting the tubing to the right length. Too short and it won't work, too long and it'll pop the die spring off.


Now, bolt it in place. Because I lubed the tubing, if you over tighten the bolt, it'll pop the die spring off. If I had left it dry, it would work better. I'm hoping that, over time, the two will sort of seize up together. The bolt squishes the heater hose causing it to expand (since it can't go anywhere else) which, in turn, puts pressure on the ID of the die spring. So far, so good. However, only time will tell. I have a few more options for securing these but I thought this was clever (and easy!) so I tried it first.

I'll report back if it turns out to be no good.

 

Is it possible to get the urethane springs with a 5/16" or 3/8" ID and drill down 3/4 the way to create an internal flange that would catch the washer? I'd be worried that the urethane would eventually pop off the bolt and hose.

 

Short answer? Yes...kinda...sorta. I'm not sure if you can get a urethane die spring in the exact measurements I'd need. You could, potentially, drill/machine out a piece of urethane with a step (which would be ideal). I believe you have to freeze it before any drilling/machining so that it actually cuts instead of tearing and flopping around. That's what you do for rubber, anyway. I could also possibly cast my own in whatever form I like.

As far as the bumper popping off? Yeah, it totally could...and likely will. I can drill it and safety wire it, put a pin or bolt through it, or any number of other options. However, it can only fall off while the swing out is open and you'll immediately notice its not there when you go to latch it closed. It's unlikely that it will have gone far at that point. I'll likely secure it so it wont fall off...I just haven't yet because, well, it's just another damn thing to do when I'm just trying to get this thing done! It's time to bring the cows home on this one. Haha.

 

A simple solution might be to dab a little weatherstripping adhesives not between the two. I honestly don't think it will be required though. Might be a pain down the road if it does pop off occasionally, but a small hurdle to deal with for something so useful.

 

Look at part number 9.9101g

Edit:

Link
https://www.google.com/search?q=9.9...KHQNGBHEQ_AUICCgE&dpr=3#imgrc=HXmoOwlg88RO5M:

 

You measure stuff in inches?

@1 Bored Clerk Very nice build!

 

Yep , I work in fractions , and decimal inches too

 

I would have thought that most of your stuff was done in the metric system

 

Not in residential construction , its pretty much still all imperial

 

OZ-T,

I just assumed you were doing me a favor by converting it for me! Haha.

 

Getting stuff done this morning. Got a bit of a late start but that's okay.


Got the second spring pin mounted. Works great!

I also cleaned up the hitch pin hole. It was a little too small (considering the powdercoating that will be on there). Cleaned up a few welds and drilled the holes for the license plate.


This is my punch list to finish the main bumper. This IS going for powdercoat on Monday!



So close! I'm ready to get this thing mounted on the truck for good. Still have to do the wraparounds but that's a much smaller project.

 

That's it. I'm done with the main part of the bumper!!




Clamp, drill, tap, counter sink. Repeat. 7 times. It's not quite as clean as I would like around the edges but it works well and I can always nerd out over the edge finish of the UHMWPE before I mount it for good.

Did some other welding/grinding to finish it off.

Took it all apart and cleaned out the bearing areas with brake kleen and knocked off as much of the little welding balls as I could get to. I imagine sandblasting will do a good job of finishing that off.


A couple of months worth of work sitting in a heap on the floor.

 

Looks like I'll have an OEM chrome rear bumper with hitch and a nice white tailgate for sale next weekend!

 

How much does that beast weigh?

 

Unsure. Let's just say it weighs 'a lil bit'.

Remember it'll be offset by the loss of the not inconsiderable factory bumper and hitch. Of course I still have to add the wings. The All Pro Expo springs can handle ALL the weight. Haha.

 

A week to ten days and I should have my parts back from powdercoat. That's all til then. I'll likely bask in the glory (assuming it all goes back together smoothly) of the finished main bumper for a week or so before I get into the wraparound parts.

 

Picked up the bumper today.

Let's get this party started!




Tear down complete. Takes about 8 minutes now...I've done it a few times. Haha.


Fluid film on any frame or bumper surface that will be hidden.


Yep, can't see a thing. Phone camera + shooting into the light = crap. Deal with it...I have to.

Anyway, the above pic shows the main bumper in place.


Time to put the UHMWPE slide plate on.


Done! Would have loved to machine one from a solid chunk as it would look perfect. But, this semi hack job will be just fine.



Stainless steel glide plates for the spring pins that lock the swing outs at 90 degrees. Nice touch...keeps the pin from killing the powdercoat.

That's it for today. I got some longer hardware for the pivots and will resume the build tomorrow after work. I would imagine that'll wrap it up for the main bumper!