Front bumper build

[JAS]

Well I finally got started making my bumper as per previously posted thread:
http://www.cntc.ca/phpBB3/viewtopic.php?f=17&t=3406

This is what it should look like when done:


I have changed the material to 1-3/4” x 1/8” wall CREW tube for the body of the bumper. I started out with DOM but could not bend it. I actually ruined a $40 length of DOM to find out. I tired 4 different bends with various techniques in my PA bender and all either kinked the tube or cracked it. To solve the problem I contacted my buddy who builds race car tube frames and roll cages. He checked out my design and confirmed that CREW will be more than sufficient for the application and the extra cost of DOM is not worth it. I ended up buying and cutting the tubes to length and got him to do the bends for me with the money I saved on material.
Progress this weekend was slow as I was fitting the main pieces to the X. I had to fine tune most of the critical bends – something that the PA bender is quite sufficient to perform. Adding a little bit more bend or taking a little bend out of the tube as I progressed.
Working in four different planes has been quite challenging in my basic shop which is really set up for woodworking. Most of the notching will be done with a Pro-Tools notcher I bought for this project but some of the notches are done with hand and eye by nibbling away at the material and doing constant test fits.
All of the critical pieces have now been tacked in place so I am hoping progress will speed up.

Here is what it looks like at this point:


I am posting my build pics here if you want to follow along:
http://s822.photobucket.com/albums/zz14 ... %20Bumper/

[the x kid]

Very nice.Hopefully your shop is warm.

[Simon]

Nice work so far!

[Jayman]

Agreed, looks great!

[Rev]

The lines look great.

[Bender]

Nicely done so far!

[studum]

Wow, wish I had:
- the tools
- the shop
- the skills

Looking awesome.

[Bow_Tied]

Very nice!!

I presume you will use MIG?

[rmarles]

Looks awesome!

[HolidayNation]

[JAS]

Well it was a very cold night in the shop since I was working on the frame brackets and fitting the bumper to the X. That means the garage door was open with half the X inside and half outside.
I sure hate taking the OEM fascia on and off constantly, so when it is off I got to get as much done as possible. I have figured out all of my outstanding variables so it was a successful night even though I froze out there.

Thank you all for tuning in and for the compliments. That makes nights like tonight much easier to take. I am using flux-core wire in my Lincoln welder. That is all I have experience with. So far it looks very good on this thickness of material.

I have updated the pictures on Photobucket. Here is how the bumper looks on the X.

[petespath]

The bumper looks good, I will have to come by and see it(when it is warmer ) You also put on some new tires. The truck is looking good.

[Adam]

That is looking good. Cant' wait to see the finished product.

[Pezzy]

Nice work, JAS!

[Scotto]

F'n eh.

Love it. Well done!

[PiDGE]

wow some nice work

[deeker]

Looks good. I certainly appreciate all the finicky angles you have to deal with.

Hard to tell from the perspective of that one picture, but does the new bumper come down lower than the stock bumper or is it higher? Really I'm just wondering how much clearance you have gained with this project, that's all.

Keep up the good effort.

[JAS]

Once again thank you for the compliments and for tuning in. Another cold one out there tonight! Not much more done other than cutting/grinding the wing end supports into place.



Pete – come by any time buddy – if you see the garage lights on stop in. I will be putting some time in on the weekend.

Deeker – the bumper sits 9” in front of the frame at an upward angle of 8 deg. Overall I will only get marginal increase in approach angle but what I do have will be solid. You get an idea of how the profile of the front changes when you look at the wheel well that I will have to trim. The picture in my last post is taken from about 8 feet in front of the vehicle and approx. 5 feet up.

The reasons that I am building it are:
1. The stock fascia plastic got ripped off when I was backing up a boat and got the front caught on a stump. The fog light assembly got broken and the light can’t be aimed anymore.
2. While doing some work in the bush I put a dent into the body under/beside the passenger headlight.
3. I want to be able to use shackles for recoveries as I hate the factory ‘hook’.
4. I want to be able to tie off long loads such as a canoe without having anything touch the body.
5. I don’t want to damage anything again as I plan on keeping the truck for a long time and I don’t want to have to fix a broken plastic bumper in the rain again.
6. I have seen what a deer does to a stock vehicle. I know I am not solving this entirely but I like my chances better with this bumper.
7. I want to add some lights and would prefer them on the bumper.
8. I like the challenge of it and learning new skills.

It has been a huge education and a neat little challenge. More to come …..

[steelcityslicker]

Now THAT is some bending and welding. Great job so far!!

[the x kid]

8 great reasons.