DIY Armor and Accessories

I am going to build a front and rear bumper along with sliders, I have no experience working with metal in this way.

I have no tools but a plan. I've done all the research now it's time to start making moves.

Plan: buy everything nessesary, practice welding, metal working, tube bending etc... Then build.

Before:







If you don't want to read everything

Pics,
Sliders page 4
Front Bumper page 4
Rear Bumper page 5
Swing out tailgate page 6
Bed Rack page 7
Recovery points, skottle, cb mount page 8

 

Nerfgun bumpers by nerf gun master

 

Do plan on building anything after the bumper?
Cost of a welder, bender, notcher, saw, material...a few grand$(no harbor freight tools)

 

Well looking at the costs I will have to build front and rear bumpers and sliders to break even.

I purchased a Lincoln electric 140hd along with a grinder, discs and safety equipment. (The welder isn't top notch but it will do the job and the price was right for getting my foot in the door)

Currently building a workbench to practice my grinding and welding

 

I might be able to cut some cost by borrowing a pipe bender from a coworker, but then again I hate borrowing tools

 

Unless your planning on doing a lot of pipe bending I would try to borrow one. Borrowing the frame at least if they don't have a die in the side pipe you want to use on your bumper. Good pipe dies are at least $250 each. So if you want to save on cost I'd use the same size pipe on everything.

 

Thanks for the info, planning on using 1.75 x .120 for everything

 

Just a quick update for the build needed to make some space to work. I saw this old table with a metal frame outside my work. Got the ok and took it.

Removed the top, Bought some nice wheels with locks.

Found some scrap tubing and begun framing.



Needed more room in the garage so demolished the outdated tool bench



Found some more scrap metal and continued framing. Added slates on the right side so I can use C clamps. the left side will house a wood top salvaged from the previous desk that will slide back and forth. Cleaned up and organized and boom!




Just need to cut and fit the wood top. Stoked on the final result. Everything is there welder, air compressor, grinder and misc tools even got hooks for my masks. The work bench can roll where it needs to go. A power strip is located behind the air compressor. So I guess gotta run one extension cord for all the tools. This little project was perfect for learning my settings on the mig.

Next step, tube notcher purchase. Also debating making sliders before the bumper. Just looks easier and more cuts allowing for more practice.

 

Just a hint welding and a wood top don`t mix well!!

 

I want to do this as well, how do you like the lincoln 140? i was thinking of getting the 180.

 

What do you mean wood is an excellent conductor! No welding no will take part on the wood side, and I don't need it to look fancy so it ok if it gets fried.

 

I'm going to give you a fair warning: once you start welding and building your own stuff, you will be forever addicted and will be unable to quit.







In all seriousness, I built everything on my truck myself and have zero regrets. Sliders, front and rear bumpers, skid plate, tire carrier, snorkel, various brackets, twin stick conversion, etc. It's the most rewarding thing I've ever experienced. And it saves a ton of money! As far as tools go there is a bare minimum of what you'll need to successfully perform your projects. My suggestions are as follows:

- Welder + gear (120V is convenient, but 220V opens up your options to stronger and bigger stuff once you're more experienced. Better to be looking at it than looking for it!)
- Grinder (for cleaning weld surfaces, removing paint, etc)
- SAFETY EQUIPMENT!! (Dust mask, hearing protection, and safety goggles. Do NOT skimp out on safety, these tools can be exceptionally dangerous).

To make your life way easier:

- Chop saw (I cannot express how much time and effort these things save.. super straight cuts vs. a grinder with a cutoff wheel)
- Tube bender (if you intend on making a tube bumper)
- Plasma cutter (great for cutting plates or making quick tube cope cuts)
- A nice big metal work surface

I would, if you can afford it or have access to one, HIGHLY suggest a MIG welder. Gasless flux core works, but makes a mess and doesn't produce near as strong or nice welds. Here are a couple pictures of my truck showing the stuff I built for it :

 

I would buy that rear bumper. It is gorgeous

 

Awesome work! Where did you get that grill?

 

Thanks for the warning but I am already addicted... Ive been working in medical device manufacturing which started my addiction and now I'm finishing up my Mechanical engineering degree.

I just got bored with learning about mechanics but never really doing anything hands on.

I perviously owned a Prerunner and always wanted tube armor but couldn't justify it as a 2 wheel.
But now with my 4x4

I have no excuses

 

The 140 is great to start out on I did a lot off research and decided to start small. With the 140 (120v) im limited to metal thickness. The 180 (220v) you can get better penetration. Penetration is key.

I took a basic intro to tig welding class at San Jose Shop Tech it cost about $120. I really enjoyed the process. I'd give the class a try if your interested.

I did a lot or research And by research I mean hours online also visited stores compared designs, prices I also bugged coworkers who have been welding for years.

Keep in mind your not just buying a welder, you need welding gloves, mask(spend extra on the auto darkening) and all the expendables it's going to add up quickly. You need to cut metal so your Guna need a grinder, and an assortment of discs, a face mask and safety glass and respirator

 

Thanks for the info! I'm in the east bay so maybe I will give that class a shot. Hoping to snag some protective gear and grinder from my dad to cut back on initial cost. But I know overall it's not cheap at first.

 

You should buy the 180, so I could use it for thicker welds and you can borrow my 140 when you need something portable

 

just saying

 

Hahahaha, I'm a grinder.