Bumper build. Finally!
09-07-2010, 04:07 PM
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Bumper build. Finally!
Started the bumper build this weekend. I have been wanting to do this for a long time, but never had the funds or the tools.
Here is the cardboard practice run.
I started with the left side and then thought it looked too bulky when I fit it with the stock bumper still on. I then designed the right side and it looked good. I then took the stock bumper off and fit the cardboard bumper and the left side looked way better so I went with that design.
Here is the top and front pieces tacked up.
Here is the full bumper tacked up and in position
Now i just have to finish the main brackets to bolt it to the frame, I already made some side brackets. I am debating whether I want to cut out spots for turn signals in the bumper or just move them to the side markers. In the future I will build a bracket that will mount to the frame behind the bumper to mount a winch, but gotta save up for that. I am also thinking about getting a pipe bender to add some tube to the top of the bumper.
Let me know what you guys think, ill add some pics as soon as I get it all finished and painted.
Here is the cardboard practice run.
I started with the left side and then thought it looked too bulky when I fit it with the stock bumper still on. I then designed the right side and it looked good. I then took the stock bumper off and fit the cardboard bumper and the left side looked way better so I went with that design.
Here is the top and front pieces tacked up.
Here is the full bumper tacked up and in position
Now i just have to finish the main brackets to bolt it to the frame, I already made some side brackets. I am debating whether I want to cut out spots for turn signals in the bumper or just move them to the side markers. In the future I will build a bracket that will mount to the frame behind the bumper to mount a winch, but gotta save up for that. I am also thinking about getting a pipe bender to add some tube to the top of the bumper.
Let me know what you guys think, ill add some pics as soon as I get it all finished and painted.
09-07-2010, 04:22 PM
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Its probably about 60 - 70 pounds based on how much the metal is supposed to weigh? I got a 4x8 sheet of 10gauge that is supposed to weigh 180lbs and I cut it in half before i laid out the pieces, so its less than 90lbs. The pictures really make the thing look more "Beeeeeffff" than it really is.
I have thought about a winch, but havnt got measurements yet. There is a ton of room behind the bumper and if i have to cut a spot out of the top that is fine. I tried to make enough room for the winch. When I make the mount I am going to use 1/4" steel so it is a strong point to pull on.
Now i just need some bigger tires to match the "beeeeefffffff" look!
I have thought about a winch, but havnt got measurements yet. There is a ton of room behind the bumper and if i have to cut a spot out of the top that is fine. I tried to make enough room for the winch. When I make the mount I am going to use 1/4" steel so it is a strong point to pull on.
Now i just need some bigger tires to match the "beeeeefffffff" look!
Last edited by SigEp4Runner; 09-07-2010 at 04:24 PM.
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09-07-2010, 04:27 PM
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yeah its a cheap @$$ flux welder that a buddy of mine sold me for $40. It works great for 10gauge, but it takes a long time to weld with. The welding wire that came with it sucked so I got the expensive stuff and it works 10 times better.
Last edited by SigEp4Runner; 09-07-2010 at 04:28 PM.
09-07-2010, 04:30 PM
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Hehe. Yeah, I've got a LincolnElectric flux core. I think the smallest one they make. I have had no problem welding 3/16 mild steel though 
I've burned THROUGH 1/8 a few times while first learning. (Still in the learning process)
I've burned THROUGH 1/8 a few times while first learning. (Still in the learning process)
09-07-2010, 04:33 PM
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I thought cutting the steel with a grinder and cut off wheels was going to take a long time, but it actually went really quick compared to the welding. I'm just glad I work at fastenal and only spent $10 on 10 of the expensive cutting discs.
09-07-2010, 05:38 PM
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I like it. Nice work. Keep us posted... 
09-07-2010, 05:40 PM
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Thanks for the coments guys, I'm really happy with how it turned out. I really couldn't just pay an arm and a leg for something i would have such a good time doing my self. Plus it will be the only one around. I have enough metal left to build a skid plate and another bumper to sell to my cousin too.
09-07-2010, 05:49 PM
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Maybe you should sell him the first ones, just in case you come up with any design improvements?
Side note. You still liking your duratracs? Any problems with them?
Side note. You still liking your duratracs? Any problems with them?
09-07-2010, 08:57 PM
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I was gonna go with the right side, but when I had it on without the stock bumper it left my front end too open. It looks cooler but it was way tiny. Maybe I'll redesign it to be a little bigger and make the next one that way.
