8274 bumper build.

[Bluegrass40]

I started a rebuild of a warn 8274 for my 40 and decided to build a bumper to go along with it.
I liked the 4plus bumper with the forward rack so I started with that as my base design but added and modified a few things to suit me better.
1.Changed the tube bend locations a bit toget it a bit lower profile in the ends
2. Changed the chamfer angle on the bumper ends to match the angle in the bib.
3. added some lights
4. removed the bumper brackets from the truck so I could hard mount directly to the frame.

here are some pics of the build (in progress)

 

[Bluegrass40]

When I started to bend up the channel, I realized that the light holes were too close to the bend line and were starting to deform so I had to cut out some squared, weld them in, bend the channel and then water jet them back out. LOL. Lesson learned.

You can see that The bottom die was contacting inside of the square light cutout. That’s what caused the forming problem.

Welded on the end caps

 

[Bluegrass40]

Here are the frame inserts. Water jet, ground to fit, drilled and tapped.

tacked it together

Then started on the tubes. This was the first time I had used a tube bender (White the help of a buddy) so we did it in 3 pieces. It was 2” 1/8 wall DOM.

 

[Bluegrass40]

 

[Bluegrass40]

checked fit prior to final weld.

I am not a welder at all. This is definitely my biggest and most complex project. So don’t judge LOL. But I figured I could learn by doing. Some are better than others and none are perfect. I my grind some out and redo them.

 

[Bluegrass40]

Almost finished product...

a few things to finish up and then powder coat.

 

[Bluegrass40]

The winch is coming along to.... Illl have to dig up some better before pics... but this I’ll hav to do for now

as it sits today.

 

[Curtice]

View attachment 2371094
checked fit prior to final weld.

I am not a welder at all. This is definitely my biggest and most complex project. So don’t judge LOL. But I figured I could learn by doing. Some are better than others and none are perfect. I my grind some out and redo them.

View attachment 2371096View attachment 2371097View attachment 2371098View attachment 2371099

Man I wish my "I'm not a welder" welds looked this good. Super impressive project.

 

[WarDamnEagle]

x2 Very nice.

 

[Varty Yo]

Beauty build!!!

 

[Bluegrass40]

Man I wish my "I'm not a welder" welds looked this good. Super impressive project.

I have a patient teacher and a facility That I get to use that has top notch equipment. Makes all the difference.

 

[Elfman]

Nice job! You've got access to some great tools there.

 

[tornadoalleycruiser]

did you custom make a "cap" to go over the snap ring on the end of the 8274 brake?

 

[mattcamp]

I'm impressed! Great work on the bumper and the 8274!

 

[Bluegrass40]

did you custom make a "cap" to go over the snap ring on the end of the 8274 brake?

Yep. Good excuse to learn to use the lathe. But man. Drilling and tapping that shaft was no joke! Very hard. I’ll see if I have some pics somewhere. It was a little thicker than I would like but I wanted to make it flush with the cap head screw I used. Over all, I was happy with it turned out.

 

[Bluegrass40]

Wire wheeled and ready for powder coat....

 

[eman375]

Nice design and it looks good on your 40!

 

[Bluegrass40]

Painted and ready for the 8274 to catch up!

 

[Garrissey]

This is freaking tight, foo.

 

[Bluegrass40]

This is freaking tight, foo.

Still need to add lights, fairlead and the beast of a winch. Probably need a lift kit for the font so I’m not dragging the front end LOL. That bumper is not light and the winch adds another 110lb.