Bumper Build (1 Viewer)

[R.E.M.]

I started on the shackle mounts. Using 1x3" cold rolled steel:

Man, drilling and tapping M12x1.75 is not fun. And I don't think I did a good job. I haven't test fit yet, but I'm doubting it'll line up nice. The drill press I used wasn't the greatest. And I'm not much of a machinist.

Not bolted in; just sitting there:

IF they fit I'll chamfer the front corners and drill for the shackle. If not I'll use these as paper weights and pay a shop to drill and tap the holes.

The rest of the bumper is competing for priority with the PSC SP1200X power steering pump. I'll just have to see how today's PS upgrades work.

 

[doug720]

If they don't line up, why not just drill them to clearance fit and through bolt them with grade 8 bolts and nuts? You can also get 8.8 metric fasteners, there just harder to find sometimes.

Doug

 

[R.E.M.]

If they don't line up, why not just drill them to clearance fit and through bolt them with grade 8 bolts and nuts? You can also get 8.8 metric fasteners, there just harder to find sometimes.

Doug

Yeah that would be a better short term solution.

 

[ntsqd]

These are invaluable for transferring hole patterns:
http://www.harborfreight.com/28-piece-transfer-punch-set-3577.html
Just a note though, they are NOT center punches (at least not these HF cheapies). Hit them hard enough to make a mark, but then follow up with a real center punch to create a real divot.

Cheap drill presses tend to be flexible, particularly in the table. The key with them is to not crowd the drill bit too much. Maintain enough force on the bit for it to cut, but observe if you're distorting the press. If you are and can't find another one to use then shore up the table with anything rigid that you can find.

When I am making both parts I always drill the first set of holes to barely clear the bolt. So if the bolt is an M8 I drill the hole 8mm. After I have both sets of holes drilled I check the fit. If all but one bolt goes in no problem (usually the case) I then drill that clearance hole bigger.

 

[R.E.M.]

UPDATE!!

So, this:

Turned into this:

and I'm quite pleased with it!

With the help and resources of another Mud and Tornado Alley Cruiser member (2fpower) I was able to do this:

Plasma cutter!

Tack welding:

The guy above is 2fpower. I'm this guy doing the finish welding now:

Decided I wanted to fill the triangle holes. Making templates:

Ended up making the templates smaller to be more inside the tube than on the front. Once again, the plasma cutter was a fantastic tool for this. Quick freehand cutting then some fine tuning on the bench grinder.

Primer:

Gloss black top coat:

The drivers side under the headlight doesn't look straight, but thats due to crunching a tree and cracking the headlight bezel. Welded the bumper level anyway. Someday I'll fix that corner. Maybe.

Nice and tight to the body. Boner bar is not too big. The roller fairlead sticks out a bit, but the only thing better would be a hawse fairlead with synthetic rope. Once again, someday.

View from inside is just right I think:

 

[sdbrassfield]

Sweet bunch of fabbing and nice looking bumper...

 

[Big Cruiser Guy]

Sweet bunch of fabbing and nice looking bumper...

Very nice. Digging the louvered hood as well.