So..My booger bumper build

[moneypit_K5]

I just started building a front bumper for the crewcab, and I thought I'd share a few pics with you guys.

And before I get any "Dear gawd those are the ugliest focking welds Ive ever seen" comments, let me preface by saying this is also the first welding project Ive ever done.

I used Dremus build as a basic template, but had a hard time getting the 2x8 rec tube he used. Instead, I used 2x8 channel.

Like Dremu, my goal was to keep a low profile, but still have a winch.

I notched like so...then bent it using my hi-lift under the rear bumper. worked great.

I did most of my cuts by figuring out what looked right while it was on the truck.

Even with 8" steel, the thing looks gaudy. So I doved the ends up to the bottom of the fender by cutting out a triangle in the face of the bumper, and bending the bottom cord up.

I wanted to dove it more than 2", but since my fenders weren't cut, they would have hung lower than the bumper.

THe winch will sit right between the frame rails. Ive been looking for a small size-hi capacity winch for awhile for this. My buddy fell into a money pinch, and sold me this brand new smittybuilt 12k for 300 bucks.

I threw it on for photo purposes today...

 

[Desert Rat]

As long as it works. I'd make some braces though from the outside ends over to the frame or the first good hit is going to collapse that bumper into your body.

 

[Hop-up]

As long as it works. I'd make some braces though from the outside ends over to the frame or the first good hit is going to collapse that bumper into your body.

+1
The PO of my K10 put a flimsy winch bumper on there and ran into a Georgia Pine, i have smushes into the body on both sides

 

[4X4HIGH]

That's a good start. What thickness is that channel? If it's not 1/4" i would highly suggest you add more material (thickness) to the section that the winch will mount to (assuming you mount it to the bumper). You did say though that the winch would sit between the frame rails but unclear if that's attached to the bumper or a separate winch mount/plate.

 

[moneypit_K5]

It is 3/8" channel, the bumper weighs about 140lbs without the winch. I could have gone with 1/4", but this was more readily accessible.

The winch will be mounted to the bumper. in my opinion, that is a better way to go- less strain on the winch mounting bolts and winch housing.

Desertrat: It crossed my mind to add brackets, i considered using the stock ones even. I dont really expect ti to bend easily though, its very thick channel. I'll figure that all out when i finish the light mounts. I plan to recess round foglights into the face.

This by no means is finished product. I had just cut the end caps freehand with a torch a few mins before taking the pics. There is alot of finish yet.

 

[dremu]

Heh, I'm famous! And you used my high-tech bending method

As for welding, it's practice, practice, practice, etc. And don't be afraid to take a sledge to your work and really wail on it. If it breaks, your welds weren't good enough

Also, some of us are clever enough to only post pix of our better welds, makes us look like better fabricators than we are

I assume you're gonna trim down the end caps so they're less ... well, dangerous to the sheetmetal? Even with bracing, a big-ass bumper like that will stay with the frame, so when the body flexes on its mounts, the sheet metal may want to kiss the bumper.

 

[moneypit_K5]

Heh, I'm famous! And you used my high-tech bending method

yeah baby!

I assume you're gonna trim down the end caps so they're less ... well, dangerous to the sheetmetal? Even with bracing, a big-ass bumper like that will stay with the frame, so when the body flexes on its mounts, the sheet metal may want to kiss the bumper.

I plan to round out the top corners a little, I figured if they were 1.5" away, id be good?

 

[dremu]

I plan to round out the top corners a little, I figured if they were 1.5" away, id be good?

If it were me I'd cross the thing up in the yard, jack one side of the front axle up as far as it'll go. (Hi-Lift's are handy things, right? ) and see how close the thing gets.

'Course, if it were me I'd not be concerned about my sheetmetal 'cuz it's crap to begin with

-- A

 

[moneypit_K5]

Well, I made a little more progress today, I got the mounts drilled and securely welded to the bumper. I cleaned it up a little too, finish welded everything, and added some pull points. In person, it is really a nice looking bumper if I do say so myself.

I plan to bedliner it to match the rest of the truck, im thinking of using that herculiner. any thoughts on it? im looking for a smoother finish, but more hardy than paint.

I just couldnt wait, had to mount it all up with the winch and such...

it sits about 1" from the body. Im not worried too much about flex, this thing doesnt get twisted up on any trails. tow rig only.

Im very happy with how tight it is in front too.

Also, some of us are clever enough to only post pix of our better welds, makes us look like better fabricators than we are

On another note, Im going to hard wire a winch control switch into my cab. Im considering using a stock k5 power tailgate switch because it is SPDT, three-position, and momentary on. I'll mount it right next to the dash fuel switch, should look pretty clean.

 

[dremu]

On another note, Im going to hard wire a winch control switch into my cab. Im considering using a stock k5 power tailgate switch because it is SPDT, three-position, and momentary on. I'll mount it right next to the dash fuel switch, should look pretty clean.

Interesting mounting of the shackles, i.e. diagonal. Donno if that's good or bad ... does allow you to pull sideways or forward without so much stress, maybe.

The weld closeup looks good to me

One tip on the winch switch ... consider putting a switch elsewhere inline in series.

The upper right is my inside winch controls. The red covered switch goes to the fusebox, and then to the black toggle in the corner (which is, like your tailgate switch, momentary center-off.) I have to flip up the cover and turn on that switch before the momentary works.

This way if you brush up against the momentary with your shoulder whilst rooting around under the seat, you're not running the winch in, stretching your winch cable or breaking something. Doesn't have to be as, umm, obnoxious as the psuedo-aircraft style switch I used, but you get the idea.

-- A

 

[moneypit_K5]

Ahh yes, my shackle angles. i went round and round on that one. I thought it looked too lame with them hanging straight down. I dont know that any one wya is better than another if the welds are good.(which, clearly mine are)

Doesn't have to be as, umm, obnoxious as the psuedo-aircraft style switch I used, but you get the idea.

thats funny you say that, because that very switch is exactly what I bought to use for the main power.

I was going to position it discreetly though, so some prick doesn't blabber incessantly, "whats the red button do? can I hit the red button? whats it do? will i get catapulted out of the truck?" the answer is yes, you will be thrown from the truck, just not like how you expect.

 

[dremu]

Ahh yes, my shackle angles. i went round and round on that one. I thought it looked too lame with them hanging straight down. I dont know that any one wya is better than another if the welds are good.(which, clearly mine are)



thats funny you say that, because that very switch is exactly what I bought to use for the main power.

I was going to position it discreetly though, so some prick doesn't blabber incessantly, "whats the red button do? can I hit the red button? whats it do? will i get catapulted out of the truck?" the answer is yes, you will be thrown from the truck, just not like how you expect.

Well, besides the additional safety offered by the covered switch, it does exhibit a certain, you know, *style*... donno if I'd call it cool factor, per se, but you get the idea.

And I like the "Yes, you'll get thrown from the truck if you use that switch" line.

-- A

 

[dremu]

Ahh yes, my shackle angles. i went round and round on that one. I thought it looked too lame with them hanging straight down. I dont know that any one wya is better than another if the welds are good.(which, clearly mine are)

Now, more usefully ... the traditional mount of mounting the shackles vertically allows them to be easily mounted to the frame, and for straight-ahead pulls is fine.

If pulling to the side, however, the shackle will be twisted and/or the pin will loaded unevenly ... versus with your mount, it'll load more evenly. Slick, even if you just did it for looks =))

-- A

 

[jonathon]

You gonna tack the bolts on the winch up?

Crackheads have been busy lately..

The fockers tried to steal the starter off a friend's truck.. the header stopped him

 

[moneypit_K5]

You gonna tack the bolts on the winch up?

Crackheads have been busy lately..

The fockers tried to steal the starter off a friend's truck.. the header stopped him

tack...meh- im going to weld on them till they are nothing but mere lumps of steel. then im going to put a skidplate in under the winch so it cant come out the bottom. And then- well you get the idea.Ive already had one winch kyped. aint gonna happen again.

 

[RudyO]

I think the bumper proportions look pretty good on that truck, especially for your first welding project.

As far as the Herculiner- I did a 8 ft bed with it. 2 coats rolled on, followed the directions. Looked good for a couple years, then started turning whitish in areas. Then started disappearing in those areas. After about 5 years over 50% of the bed was showing again.

I don't think it's a bad product. I should have added a couple more coats and sprung for the gun to spray it. It was also parked outside year round in Colorado heat and sun.

Just my experience with it.

 

[supersize75k5]

I would not use herc on the body or any other surface I wanted to look at while holding a 2 litter of soda and walking up on a my truck.

 

[moneypit_K5]

thanks for the heads up with the herc. I know theres gotta be some sort of liner out there that works great.

I would not use herc on the body or any other surface I wanted to look at while holding a 2 litter of soda and walking up on a my truck.

no problem there, I dont plan on walking up on a my truck with anything smaller then a 3 gallon jug of soda. And if'n I do walk up on a my truck with a two litter of soda, I'll be sure not to want to look at any surface on it a my truck.

 

[moneypit_K5]

Now, more usefully ... the traditional mount of mounting the shackles vertically allows them to be easily mounted to the frame, and for straight-ahead pulls is fine.

If pulling to the side, however, the shackle will be twisted and/or the pin will loaded unevenly ... versus with your mount, it'll load more evenly. Slick, even if you just did it for looks =))

-- A

THat was my train of thought actually...dude I went round and around on this one.

 

[jt512]

thanks for the heads up with the herc. I know theres gotta be some sort of liner out there that works great.

Look into AL's liner, Bryan (Blaze) in the vender section can take care of you. As far as I am concerned it is the best DIY liner out there, you can "adjust" the texture by changing the air pressure when you spray it, and it comes in lots of colors and is not supposed to fade from UV exposure. I actually sprayed the underside of my K5 tub with it and could not be happier, the inside will also get shot in AL's as well.