In October of last year I sold my old bumpers to buy a welder and build new ones. I started on the rear but it is not yet finished. The front however is. This was almost all cut out with an angle grinder. The holes were cut out with a plasma cutter at a shop down town.

Costs:

Steel: 300 with some left overs
Gas: 188.08 with buying a larger tank, would have only been 40 if i started with the larger tank and some for a set of sliders and the rear bumper
Disposables(grinding discs, flapper wheels, cutoff discs, tips, wire, drill bits): 148.07
Fasteners all Grade 10.9 M14: 40.88

Total: 677.03

Yea I feel its a little much but I'm ok with it for the first one. It turned out nice. It is held on with 5 bolts on each frame tube. Two in the bottom, two in the end cap, and one going through horizontally. The end cap mod goes into the frame about 5 inches, and is welded entirely around the front of the frame and through four holes in the side. On to the pictures!!!


My end cap mod:

From the beefed up same shape as the factory:







Now cleaned frame


This is the piece that goes into the frame.




Welded in



Now onto the front bumper.

Bumper in pieces!!!!
Dirty


Clean




Bottom of mount, it attaches to the two factory bolts for the tow hooks.



Winch Plate


Vertical mount top plate support


1" Shackle mounts, drilled with a one inch hole saw


Front plate



Top Plate


Bottom Center


Reciever


More Tomorrow

 

SICK!!! Especially impressive that you did all that with an angle grinder. Did you start with a CAD drawing or cardboard mockup at all?

 

Zelephant, I did indeed start with a CAD drawing, one created by bandit runner....

 

Here is the rest for now.







Bumper tacked together


Winch that went in after being put back together(it was broken)

All Welded Up


My Welds


95% Finished Product




I will get some more pictures today. Some of the mounting bolts, and other bits that are not visible from the above pictures. I also put blinkers in it yesterday. I still have to weld on the side braces and fog light pipe and bracket.

Also, it would not be kind of me to not give credit where credit is due, I used Bandit Runners CAD design for this. He sells the plan as a you build it, however mine looks quite different and doesn't have as much steel removed.

 

For paint I used this brush on rustoleum stuff called Hammertone. I like it very much! It can be bought from Lowes for 15 bucks a qt. Its a little pricey but worth the money. I put the paint on at 1030 at night well below recommended temperature application. It still turned out nice. There is a few funs but nothing that can't be fixed the next time it comes off.

 

Nice work! I thought the top plate looked familiar - I went through the design process with BanditRunner too, but couldn't dedicate the time without a front bumper. Way to get it done, man

 

Thankfully, im a student right now. And an online one at that. So I got my school work done and worked on the bumper. I have about 50-60 hours working on it. I did it over a two week period.

 

2 weeks isn't bad at all. I think it took me 6 months to do mine. What did you end up using for turn signals?

 

Bandit, I used something from some LED store. They were cheap and small. Unfortunately I don't know how bright they are. As I havent plugged them in.

 

Bandit, these are what i used.

 

Nice Bumper! Im building one too right now and debating on putting the fog light holes in or not. Ill be interested to how your setup comes along.

 

Its going to be a bit before I finish the fog light holes, and a few other bits. But here is a couple other pics I havn't posted.

The five mounting bolts on Passenger side


Another front shot with both blinkers


The Side hoops through the top plate, welded to the bottom

 

looks good how it all came together nicely