Bumper build

when its finished I plan to take LOTS of pics from every angle and post the weight, hopefully this weekend

 

Truly inspirational...you make it look so easy that I can't help but get started building my own. Do you have much welding experience, or have these bumpers been a learning project for you?

 

I have a bit of welding experience, and fabrication experience, I've build 2 trucks from the chassis up, but really, these bumpers are fairly easy, it takes a lot of time and patients, cutting and fitting and cutting again until each piece is exactly the way you want it, start with cardboard and transfer it to steel when your comfortable with what you have, don't take any short cuts and you'll be fine. Tack it all together, and once the entire bumper is complete then weld it all together, I had to take a few pieces off to reshape them, that was a lot easier when it is only tacked together. When it is time to weld it all together only weld about two inches at a time and move around to spread the heat and not warp the steel, your going to grind most of the front welds away so it needs to be welded on the back for strength. the big piece of advice is TAKE YOUR TIME, the more picky you are the better it will turn out,

 

Well here it is, welds are ground down, I didn't smooth them out with a flap disc because it will be coated in bed liner so it will have a rough finish anyway. I sprayed it with a flat black primer, it still needs a skid plate and holes drilled for D-rings and the lower mounting holes but seeing that it won't go on the truck until I get some coilovers it's finished for now...

 

Looks awesome man good job

 

almost forgot, without a skid plate it weighs exactly 100lbs, add a few pounds for an aluminum skid plate and bed liner, and 80lbs for the warn vr8000 that will find a new home inside the bumper, that should send the MPG south lol. what's next? in the near future i'll be starting my high clearance rear bumper with swingout.

 

Sounds like sliders and full skids are next after that, great job on the bumper looks factory.

 

Yup, sliders and skids are on the to do list

 

Looks great man! If your still interested in passing on some dimensions or any other info when you get some free time that would be awesome. Can't wait to see the rear bumper and see what you do with the swing out!

 

Lets start with the mounting plate
It measures 8"x37.5", I used the factory bumper reinforcement to mark the holes, I trimmed it to match the frame shape later in the build and cut a large opening in it for air flow


The winch plate was originally the same width as the mount but was later trimmed down to 10"x31.5". Then the gusset fits between the 2 outside mount holes and the inner mount hole, there is a small gusset in the center as well

The front plate is 7" high, 31.5" long at the bottom and and 33.5" at the top, looking from the side the front plate is angled out 2" at the top

The front plate is gusseted to the winch plate, I drilled holes in the gussets to try to keep weight down, the plate that angles back from the top of the front plate is 1/8 thick, 3"x33.5 not sure of the angle, the top is 9" from the winch plate, this is the height that worked for me as it is level with the bottom of the grill, then I cut a piece to fit between that and the grill, I believe it was 5"x33.5"x1/8" but you'll have to double check that one, as your building
,
Once you get to this point you'll have to get out the cardboard and start making your desired shape to fit around the headlight and fill in under that, I don't really have any measurements for the putter section, I cut cardboard to fit then cut 2 pieces from steel (one for each side) cutting two from one stencil makes it easier to make the sides symmetrical

 

Hope that helps

 

Great job! That all certainly helps! I look forward to checking out your next build threads!

 

Ill probably keep this thread going for the rear bumper as well

 

Looks good

 

Yes please.

 

Well here's my high clearance hitch receiver that the rear bumper will be built off



I still need to decide if I'm going to cut the bedsides or build to fit the stock configuration

 

So after adding some shape and fully welding the structural parts I noticed the main support had bowed from the heat so I'm not sure if I want to try and work with what I have or start over from scratch...

 

So the plan is to keep going with what I have and NOT to cut the bedsides, should have pics tomorrow night

 

It needs a little trimming and welding but you get the idea

 

But.... what sucks is those of us who own these tools and currently live in apartments due to relocation for income to even afford a Toy. We Got No Garage........We are misfit fabricators who dream of having enclosed space. Great work.