Finally started my front bumper

[canman]

Recently I picked up what looks like a Chinese copy of a TJM front bumper designed for a Nissan Patrol. Before I purchased it I did a trial fit up on a fellow mudders rig. It fit on the frame rails, but was about 3 inches too low. This afternoon I got around to doing a fit up on my truck. Unfortunately, the front contour did not fit well with that of the Lexus. After some thought I decided to start cutting it up. I'll likely just use it for a template to customize it to my liking, and then cut up new steel for the real deal. I have 1/4" and 3/16" plate I purchased several years ago that I'll use including the 1/4" piece I had bent to fit the frame rails for mounting my winch. I'm not sure of the thickness of the steel used in the name brand ones, but the steel in this thing is less than 1/8" thk. Attached are some pics

 

[canman]

Another pic.

 

[canman]

One more...

 

[canman]

Got my winch plate mounted and mocked up the winch section and one wing. I was very lucky when I drilled out the four mounting holes (1/2") for the M12 bolts - everything lined up to my surprise. I'll likely add some more holes to pick up the orig bumper brkt mtg bolts. I have a new found respect for those that do this kind of work and realize that $1K or $2K for front/ rear bumpers is reasonable. Attached are some more picks of the mock-up...

 

[canman]

Side view. I'll probably will have to trim back the wing a little to allow more clearance for the tire and to better follow the contour of the wheel well arch.

 

[canman]

Last one.

 

[nigelsiam]

Looks good so far....Mock it up as many times as needed so you don't waste your materials and time. After it's all done give it to me! haha

 

[canman]

I've been delayed a bit because I ordered a Simadre plasma cutter from Ebay which I picked up on Friday. After some futzing around on the weekend I got it working. It's pretty amazing for what it cost. I also got myself a Freud Demon steel blade for my Bosch Skill saw which I used tonight for the first time. It's truly remarkable, and I was able to cut out two of my side supports out of 1/4" plate without any problems. I need to get some parts bent which I'll probably drop off this Friday.

 

[Offroads4x4]

The design looks great. I like how your winch will be fully covered.

One question comes to mind. Do you want it pushed that close to the body/fenders just in case you tap it against something like a rock or someone backers into it? It looks like it might hit/dent it and then flex back out if bumped hard. Just a thought.

I really like how clean the overall look is for sure. Nice job.

 

[canman]

Thanks for the comments. Your're right. I've spent tonight making more cardboard patterns to increase the distance between the bumper and body. I'm trying to keep the distance around 3/8". The top piece for the winch will either be removable or hinged so I can view then cable and make sure it's spooled on the drum properly.