Bumper Build Thread

[stockk5]

i also don't have a tubing bender but i made a stinger for my bumper by cutting slots in the tubing almost every 1/8th inch then i bent it around a tree and welded it up ground it down and then a tiny bit of bondo and it came out great. I think it works great for a bumper application! here check it out this is w/ a 4" angle grinder

 

[joshthemule]

Looks sharp. That's a good idea. I'm a little late to try it but I'll keep it in mind.

 

[dbabicky]

looks sharp !! I likey !!!

 

[joshthemule]

First, I'm a big looser for posting this on New Years Eve but if you are reading tonight, well...welcome to the club.

So, Here is my progress. First I pulled the bumper off the frame and fished up all the welding. You'll see that spectacular welding in other pics.

Next on the list was to make the end pieces. After I cut them at the right length and angles, I beveled the ends for the butt weld.



next I started laying them in place and tack welding.


From there I didn't take any more pictures until I mounted it on the frame but you get the drift. Just lots of measuring and cutting and welding. I ground down the welds where I could on the butt welds just to make it look like one piece.

Here are the rest of the pictures.

 

[joshthemule]

More pics, You can see my grinding job. Its nothing pro but I think it will last.







I need to clean up all the wiring under there.

 

[joshthemule]

So here you can see my welding. Its all done on a Millermatic 140 and I didn't throw the thermal protection at all. I just go nice and slow.


And here you can see that I maintained a pretty good departure angle. I've drug that old receiver hitch over more rock than I care to remember. I am in bad need of a skid plate on the fuel tank.



Next phase is the swing out tire carrier. I'll start on that in a few weeks I guess. Also, I need to put a plate on the end of those tubes, and build some extra support for the rear of that receiver tube.

Well let me know what you all think. Its my first fabrication project. I'm pretty pleased so far but who knows if it will hold up?

 

[joshthemule]

BTW, I'm thinking of building these to sell. I'd like to find someone willing to buy one at cost (cost of materials) so I can get one more under my belt and refine the idea. It would be a design build so to speak because not everyone would want the pintle hitch or the receiver tube. PM me inf interested. (Must be someone within an hour or so from Manassas.

 

[Big Blzn]

Josh, I think that looks really nice. The more it progressed the more I understood what the hell you were trying to do and I think it looks great. Looks like you may want to beef the pintle plate up a bit rather than just being welded to just a top and bottom tube. Unless the magority of the towing will be from the clevis points. Good job.

 

[StevoandaRedK5]

I really like it, if I lived nearby I might take you up on that offer. I did get some ideas for my bumper just reading through though. Great job josh

 

[joshthemule]

Josh, I think that looks really nice. The more it progressed the more I understood what the hell you were trying to do and I think it looks great. Looks like you may want to beef the pintle plate up a bit rather than just being welded to just a top and bottom tube. Unless the magority of the towing will be from the clevis points. Good job.

Thanks for the input bro. I was thinking of a basic triangle plate on each side that holes cut in to wrap around the tube and weld to the sides of the pintle plate. Imagine a triangle with cutouts on the corners from a hole saw, the 90 degree angle will be on the top of the pintle plate and the long side of the triangle will go from the bottom of the pintle plate the the top rear tube. Or I've thought about doing a square plate onthe either side of the pintle with the corners cut out to contour the tube. That would reinforce the pintle plate and the receiver tube.

 

[joshthemule]

I really like it, if I lived nearby I might take you up on that offer. I did get some ideas for my bumper just reading through though. Great job josh

I hope people are getting ideas from it. What I want people to know most of all is that I have no clue what I'm doing. That being said, if I can build this, anyone can. This has been a lot of fun but in the back of my mind I've wondered if this is just a trial run and I'll end up building another version. **** I don't know. I'm just having so much fun building.

 

[Big Blzn]

Josh, I just was thinking about your mounting plates. THey look like 3/16" or 1/4" and I am thinking that you need to beef up the mounting plates for side loading strength. Say you were stuck and the only way to pull you out was from an angle to the rear you may have the possibility of torquing the entire bumper to the left or right. To strengthen my custom front tow point I cut two (each side) 1/4" X 1" X 8" long plates and welded them on to the 3/8" mounting plate like the attached picture shows. This should help with side loading as well as keeping the mounting plate from tearing at the sharp corners on a hard tug. Actually I built the thing so stout I think the frame ends will rip off before the hitch breaks. Look at my pic to see what I am talking about and maybe think about this idea. Just a thought and your bumper rocks.

 

[joshthemule]

Big Blzn, thanks again. I did think about that and you mentioned one thing that I wanted to avoid. I definitely want my bumper to break, tear, bend...before my frame does so there is that fine line of being just strong enough. If you look back the pictures where I modified the rear part of the frame, you'll see the frame comes to a point and there is a bolt hole near that point. That point actually protrudes about half way into the bumper just above the shackle mount tube. I think that will keep the lateral forces at bay. Also the tabs on the frame brackets that are bend over at a 90 degree angle also serve this purpose. I do like your idea though and I may at a rip that runs from the rear of the shackle mount tube to the rear of the frame bracket.

 

[BulldogK5]

Have you covered the ends with anything yet? What are the plans if not?

 

[joshthemule]

Have you covered the ends with anything yet? What are the plans if not?

I just haven't had time to work on it the last few weeks. YES the ends will be capped with a 3 1/2 X 3 1/2 piece of plate. Also, the top will have floor plate. Once I get that on, I'll start on the tire carrier. I've got a quote to get it powder coated in the end.

BTW Bulldog, I've been jealous of your red blazer for a long time now. I'm glad you chimed in.

 

[BulldogK5]

I just haven't had time to work on it the last few weeks. YES the ends will be capped with a 3 1/2 X 3 1/2 piece of plate. Also, the top will have floor plate. Once I get that on, I'll start on the tire carrier. I've got a quote to get it powder coated in the end.

BTW Bulldog, I've been jealous of your red blazer for a long time now. I'm glad you chimed in.

Thanks for the compliments. Let us know on the approximate cost to powdercoat. I am thinkng of taking my front bumper in to be done since it has faded so bad.

 

[joshthemule]

Thanks for the compliments. Let us know on the approximate cost to powdercoat. I am thinkng of taking my front bumper in to be done since it has faded so bad.

I took it in to a place called Extreme Powder Coating. I told them it would have a swing out tire carrier and he quoted me $250 for flat black. That includes sandblasting and prep. He said that is approximate and he'll give me an exact quote when I have the tire carrier done and bring it in. I'll let you know.

 

[motomech]

Subscribed...Killer bumper!..

 

[holtzy]

very nice bumper, man!!! Looks nice and functional as well...Cheers

 

[joshthemule]

IN case you haven't noticed, I haven't done a thing to the bumper in a few weeks. I'm assembling parts to build the swing out tire carrier but its slow going. Not sure if you heard but its redonkulously cold up here this week so I'm avoiding the outdoors as much as possible. So, here is the really exciting yet depressing news. My wife gave my the ok to buy a tube bender now that I've cut and welded 6 of the angles I could have bent. Oh well, it will still be strong and the next one I build will be bent in those places. The offer still stands to build one for any of you at cost. I just want the practice before I try to sell one and make money on it. I've got several ideas to refine the build and make it stronger.