Can't buy the bumper I want, so I'm going to build it...

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Is there a list to join for the bumper.... I'm interested and I don't live too far from Alabama, I'd do the drive!
 
Looking forward to those final pics!
 
crappy blackberry pics from today...

7018 stick = stacked dimes on the frame bracket
pic10.jpg


fitting things up...
pic11.jpg


getting there. just a little more wing trimming...
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some 6010 stick on the 1/8" plate on the insides:
pic13.jpg


more 7018 stacked dimes- this is on the outside where the 1/8" sheet meets the 3/8" plate.
pic14.jpg


7018 on the winch plate - not a high-stress piece, just for placement.
pic15.jpg


final shop fitting...
pic16.jpg


profile:
pic17.jpg


with a little black paint and at home...
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i'm really pleased w/ how the lines turned out.
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mo' betta pics coming tomorrow. weather is supposed to be nice and sunny, so you'll see more details in the black that just don't show up at night.
 
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factory horn/endcap on frame is retained. you will have to drill one hole in the frame for the winch bracket - only modification to the truck.

winch plate will bolt from the 1/4" thick winch plate, thru the frame, and thru the 1/4" thick bumper bracket riser on the other side of the frame. it will also attach to the frame crossmember in front of the radiator, so it's pulling from 4 points on the frame.
 
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factory horn on frame is retained. you will have to drill one hole in the frame for the winch bracket - only modification to the truck.

winch plate will bolt from the 1/4" thick winch plate, thru the frame, and thru the 1/4" thick bumper bracket riser on the other side of the frame. it will also attach to the frame crossmember in front of the radiator, so it's pulling from 4 points on the frame.

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How much my friend, raw steel (no paint or powder). What sized winch you be using? Thanks
 
factory horn on frame is retained. you will have to drill one hole in the frame for the winch bracket - only modification to the truck.

winch plate will bolt from the 1/4" thick winch plate, thru the frame, and thru the 1/4" thick bumper bracket riser on the other side of the frame. it will also attach to the frame crossmember in front of the radiator, so it's pulling from 4 points on the frame.


will there be instructions with the bumper? Just to make sure no mistakes are made during installation
 
will there be instructions with the bumper? Just to make sure no mistakes are made during installation


The steel pieces that are bent and cut in the package would have instructions right? I dont have any kind of welding equipment so I'd have to go to some kind of shop to get it done


bamachem said:
Most definitely. CAD sketches of how they fit together, etc, step-by-step text along with pics, etc. Just no scale drawings with dimensions, etc. If someone wants to copy it, they'll have to get their hands on one to copy the dimensions, just like they would have to do for an ARB, etc...

already covered that...

for clarity: two bolts per frame mount into OEM location for tow hooks, four bolts on the winch bracket (two into OEM winch mounting holes, two holes to be drilled into one side of the frame rails), then four bolts to hold the bumper to the frame mounts. 12 bolts total. simple...
 
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How much my friend, raw steel (no paint or powder). What sized winch you be using? Thanks

I'll get back to you, but probably $100 or so cheaper than the finished, PC'd bumper.

It has a standard 10"x4.5" winch bolt pattern and hawse fairlead mount. Any typical 8000-10000 lb winch should bolt right up. I have to finalize some of that by week's end, but it's very close to being a final design.
 
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didn't get a chance for any decent pics, but here's a couple more w/ the HELLA 2000's on it...

pic25.jpg


pic24.jpg


pic23.jpg
 
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I haven't put it on scales yet, but it's WAY lighter now that the center section is 1/8" plate.

I would estimate that the bumper is about 60-65#, winch bracket would be 20-25#, and each of the mounting brackets about 5# each. Total is probaby just under 100#. Next time it's off, I'll get an accurate weight for everything.
 
Sounding really good and looking very nice. Am looking forward to the better pics and final pricing. Also looking forward to seeing all of the "holes" filled with their associated hardware. Gotta have something that I can show the missus to get her blessing.
 
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LOL. Just working out the details on the mounting design for the fogs right now - total pain in the ass. I also have to pull it back off and buff out the entire thing to remove any slag, etc for final powder coating. The rattle-can on there is just to keep the surface rust down while testing out flex, fitment, etc. Winch bracket is finished, and I will be adding that to the frame next time the bumper is off.

Thinking of using some of these (but w/ black housings) for some custom fog lights integral to the bumper. All-LED with polymer housing. 380 Lumens each, and only draw 0.6 watts each.

I had some of these on my boat and they are BRIGHT and the spread is excellent.

Single-BackWire.jpg
 
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another style housing w/ the same LED panel that could be used. using these would probably add $150 or so to the price of the bumper.

MarineLED-Spreader-BLK-1.JPG
 
Wow, those LEDs put out enough to replace a fog light? :confused: That's awesome if true! :D
 
What about this? It would be 760 lumens and would have an effective distance of about 80-100ft (about like two conventional 55W fogs). It would draw about 1.2A, so it could be run on the factory switch or a custom switch and wouldn't run the battery down for utility usage...

pic25-led-fog.jpg
 

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