Razor One's Armor Build Thread (1 Viewer)

[Razor One]

Welded tabs so the bumper can rest on the top of the frame rails. Now the bumper just slides on or off. The tabs also add rigidity in case of a collision.

Almost ready to blast and paint!

 

[Razor One]

Almost ready for bedliner!

 

[Razor One]

Bedliner!

 

[Razor One]

Hardware on!

 

[Razor One]

My original plan was to paint it tan, but someone I highly respect said to leave it black for a week to see if I like it......

So black has one week to win me over.

If I paint it tan, I'm just going to use regular krylon camo tan paint instead of bed liner. Over time, the tan will get scratched up, showing the black bed liner underneath. I don't baby it, and I want people that drive slow in the fast lane to know that. I thought of even scratching up the tan on all the corners with a stainless steel brush, to speed up the process.

 

[Dan_J-spec_fj62]

That came out nice! I've been watching your and Booger weldz's from the scrap bin build... thank you for keeping up with this thread!

Dan

 

[Razor One]

More pics of the finished product.

 

[Brentbba]

Nice in black IMHO! Do love the double bottle openers!!! Great addition.

 

[Razor One]

Started on the rear bumper today. I think I'm going to do a tire carrier, too, but I'm not sure yet.

Before

Tire out!

Tow package off!

Cutting off bits left over.

Bare frame rails.

I have everything I need to design and build, now. Tomorrow I'll start the foam board process, again.

Can I cut this thing off?

 

[Razor One]

I have some ideas in my head for how I want to do the tire carrier. I'll probably do a swing-down carrier like Nay's:

 

[Razor One]

Okay, so I've started R & D on the rear bumper. I'm going with a swing-down design that allows me to use both the tire mount as a tailgate/utility table (when folded down), while still clearing the actual tailgate when it's dropped. So far I haven't seen a design like this, but if all my measurements are right, this should work pretty well.

It shouldn't be extremely heavy either. I expect it to be about what my front bumper weighs, not including the tire. Because I'm not sure how much sag I'll get, I have the OME heavy springs on standby and the mediums on already. If I had to guess, I expect to keep the mediums.

 

[Razor One]

Progress:

This is how the swing-down latch will work. I'll have around a 1" pin on both sides that go through the tabs in the arms and straight through the bumper.

The hinge will be a 20" long section of 1.5" schedule 80 pipe inside a 2" schedule 80 pipe. When both the arm and the tailgate are dropped, it clears the tailgate by a 1/2".

I haven't started working the angles on the wings yet. The tire will mount here:

And the whole tire will take up about this much room dead center. I'm aware that this placement will cause some problems.

 

[Razor One]

Update: Wow, it's almost been 8 months and I kinda had to put welding on hold. Now that I have my degree in Biochemistry, I have some time off. Here's some pictures!

Tried to cut the tabs off the tow package to use it as a cross beam, but something didn't look right, so I scrapped it.

Couple days ago welded up 11ga rectangular tubing to some 3/16" plate and bolted it up

Yesterday, I took a torch to some scrap 1/4" steel to make the wings. I'm about to tack up both sides to see how it looks and make changes from there.

After thinking about it, and doing some pricing and R D, I decided to mount the tire carrier inside the cargo area. I just don't want to deal with the issues of having a swing out or swing down. So right now, I'm just designing and building the bumper, and I'll go from there.

I'm waiting on an extra pair of hands to make sure I tack everything up right in a little bit. Stay tuned.

 

[Razor One]

First side pieces tacked up

Working on cutting out the other bits, and getting the other side tacked. Should have more by the end of the day.

 

[Razor One]

So I didn't get to it today. Had a few things come up, but I'll get to it faster this time than the front bumper. I'm really looking forward to getting it finished so I can start the fab work on the tire carrier. I ordered a spare 315/75/16 Goodyear Wrangler Duratrac that I need to mount inside the cargo area, and I think while I'm at it I'll go ahead and put a shelf for a spare gas can, and a spot for ammo cans on the other side.

 

[baldilocks]

Nice mock up! Subscribed!

 

[Razor One]

So I tacked up the other side tonight, and I'm a little dissatisfied. Even after adding the rest of the pieces, the bumper looks like it's missing something, but I don't know what it is. I'll have to take a look at it tomorrow in the daylight, when I can work on it some more.

 

[Razor One]

So I had some help, but I think I know what I was missing. Check it:

Ignore the rust, that piece isn't long enough anyway, but you get the idea. I'm going to reinforce the rectangular tubing with some 3" angle iron to close the gap, and give a better surface area to step up on. This was what I was missing.

 

[Razor One]

Worked on the bumper some more, today.

Ground off the left over bits from the cross-member.

Marked the bumper for a few minor cuts.

I cut 3" angle iron to the correct length and it's almost ready to be tacked up. I'm going to tack it where it's flush on top, after I take the surface rust off.

 

[Razor One]

I built a small welding table to make this next part easier.

Tacked!

Mock up

Now for my favorite part... Coming up next!