Rear Bumper slapped together in 4hrs!
01-18-2009, 12:54 PM
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Well if the images ever get fixed it will show better but here's what I did.
Used a Calypso waterjet, Accurpress, Accurshear, and of course Miller mig welder.
I may have to upgrade later but we will see, I waterjet 1/4" plates with bolt access holes and welded them to the stock brackets to box them, they seem very strong, I plan on testing them to see if they can indeed hold up.
3/4" steel bumper brackets were then waterjet that incorporate the shackle holes, these "poke" through the bumper and were welded front and back. This puts any pulling pressure on the shackles directly on the bumper mounts, bolts (which will be upgraded) and truck frame. Seems like it should work.
The bumper itself is 3/16" steel cut on the waterjet in four main sections with reliefs to bend the upper and lower sections around the sides. The press was then used to accomplish the 90 degree bends and the shear was used to cut to small lower pieces that we couldn't bend around due to the odd shape.
After the pieces were bent and cut they were tacked together on a prep table, the brackets were thoroughly mounted level on the truck and the bumper was mounted sliding over the mounts through the relief holes and tacked level.
It was then removed from the truck and finish welding was completed, it will go for powdercoating this week.
Its a very basic design that was laid out very quickly using the waterjet's software, this project wasn't planned but was done on-the-fly at a friends shop because it seemed like a good way to kill a Saturday afternoon!
Almost forgot.....the "grill" looking holes are for 4" Hella lights that will be installed inside the bumper and the two strips are 1/2" wide which should protect them nicely.....I love waterjets!
Used a Calypso waterjet, Accurpress, Accurshear, and of course Miller mig welder.
I may have to upgrade later but we will see, I waterjet 1/4" plates with bolt access holes and welded them to the stock brackets to box them, they seem very strong, I plan on testing them to see if they can indeed hold up.
3/4" steel bumper brackets were then waterjet that incorporate the shackle holes, these "poke" through the bumper and were welded front and back. This puts any pulling pressure on the shackles directly on the bumper mounts, bolts (which will be upgraded) and truck frame. Seems like it should work.
The bumper itself is 3/16" steel cut on the waterjet in four main sections with reliefs to bend the upper and lower sections around the sides. The press was then used to accomplish the 90 degree bends and the shear was used to cut to small lower pieces that we couldn't bend around due to the odd shape.
After the pieces were bent and cut they were tacked together on a prep table, the brackets were thoroughly mounted level on the truck and the bumper was mounted sliding over the mounts through the relief holes and tacked level.
It was then removed from the truck and finish welding was completed, it will go for powdercoating this week.
Its a very basic design that was laid out very quickly using the waterjet's software, this project wasn't planned but was done on-the-fly at a friends shop because it seemed like a good way to kill a Saturday afternoon!
Almost forgot.....the "grill" looking holes are for 4" Hella lights that will be installed inside the bumper and the two strips are 1/2" wide which should protect them nicely.....I love waterjets!
Last edited by fastkevman; 01-18-2009 at 12:56 PM.
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01-18-2009, 01:08 PM
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01-18-2009, 01:21 PM
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01-18-2009, 01:39 PM
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Ironically I told my friend that we could easily sell these, he just laughed, he could care less about trucks other than he uses them for work.
The design is simple and the waterjet makes it just too easy.
His shop is very busy and I was lucky to get some "play" time there!
They have never made a bumper or any other product of that type there and all his guys thought it looked cool, I plan on taking some real good pics when its powdercoated and mounted.
I would love to make some more stuff there.....we'll see, the gears were DEFINITELY turning in my head after getting the hang of the design software!
The design is simple and the waterjet makes it just too easy.
His shop is very busy and I was lucky to get some "play" time there!
They have never made a bumper or any other product of that type there and all his guys thought it looked cool, I plan on taking some real good pics when its powdercoated and mounted.
I would love to make some more stuff there.....we'll see, the gears were DEFINITELY turning in my head after getting the hang of the design software!
01-18-2009, 06:12 PM
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01-18-2009, 06:24 PM
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01-18-2009, 07:11 PM
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I have a Warn front winch bumper already, I couldn't find a rear bumper that I liked and mentioned it to my friend and he told me to make whatever I wanted.
I somewhat patterned it from the rear bumper that Warn does make.
That bumper doesn't have all the features that I wanted and its almost twice as expensive as the front one......I have no idea why.
I paid for the materials that I used and am not sure how much the powdercoating will be yet but my guess is that I will have about $300 in this when done.
My Warn bumper cost $550 and the cheapest quote I got on the rear one from Warn was $850 not including shipping.....seems odd but its true.
I have seen others with the same winch bumper as mine but never the Warn rear....now I know why!
I somewhat patterned it from the rear bumper that Warn does make.
That bumper doesn't have all the features that I wanted and its almost twice as expensive as the front one......I have no idea why.
I paid for the materials that I used and am not sure how much the powdercoating will be yet but my guess is that I will have about $300 in this when done.
My Warn bumper cost $550 and the cheapest quote I got on the rear one from Warn was $850 not including shipping.....seems odd but its true.
I have seen others with the same winch bumper as mine but never the Warn rear....now I know why!
Last edited by fastkevman; 01-18-2009 at 07:12 PM.
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