WOW. $250.00 is way better. I would have thought the steel would have been at least twice that. My beads aren't that bad. The biggest obstacle would be getting the 220 into the garage. The main panel is all the way on the other side of the house. If your bumper is your first try and without a Plasma, then its damn nice. There was a guy a few months or so ago that was going to make cut out kits to send out. They would show up ready to weld. It was on MUD. I think the guy lived in ID. He ended up flaking out on the whole deal. I think he had 9 orders. Might be a nice sideline business.
I donno what steel shops you have down there, but up here in Reno, we have a place called metal masters. Theyve got awesome prices, and if you give them dimensions, they will cut the steel for you.
Youll need a TON of 4.5 in cut off wheels, almost as many flap disc sanders, and a grinding wheel. Aside from that, a drill press for the frame tie ins (not absolutely necessary, but VERY NICE) and a hole saw.
I tied into the frame with 1/2 in plate. There are 3 rivets youll need to grind off and pop out and then bore out for you bolt ins. Youll also need to cut out the stock x member. You could leave it, but it will set your bumper out a bit further. If you build the bumper stout, you really shouldnt need it.
I added a trailer hitch on mine for emergency ONLY. Its is obvioulsy NOT rated.
I used 2x2 1/4 in wall for the swing outs...I would do a 2x3 .120 wall tube for those. It would lend a little more rigidity.
I would also recommend using DUAL swingout (like I did) if youre going to do a set up with BOTH gas and tire carriers. If you have BOTH on a single arm, that is a LOT of force exerted on the spindle end.
Also, for the body of the bumper...I used 5x5 in tubing...DO NOT go this route. Steel has memory. I obviously cut mine apart, and I had warping issues related to this phenomina and had to do a TON of extra work to get it "straight". Use 3/16 plate and if you wanna save time, have metal masters cut the dimensions. It may be a little extra for cut charges, but saves a TON of time in the end. If you like mine, I can give you the dimensions off of that.
It takes some time to do and get what you want, where you want it, but...if youre saving that much money...Who the F cares.
I F'd up and used the wrong latch. You need the LOCKING latch, and mine is not, so I have to use a retainer strap.
Just DO IT. Half the battle is OWNING a welder, and since you have one, there is really NO REASON to pay that much money for one of those bumpers. Not that they arent nice...dont get me wrong...but, its still a LOT OF MONEY for something that a little bit of time and effort wont save.
Another good idea is to go hit up steel fab places and ask to pick through their scrap bins. This helps spare some of the costs on the steel if you find the right peices, and also will allow you to go out and practice your welding on crap you dont care about. Look in the yellow pages for custom fence makers, steel fab shops, even if there is a construction site with steel workers aboard...tell em youre learning HOW to weld, and most likely they will not only let you take some scrap, but will also lend some pointers.
Im not too far from you, so if you get in a jam, I could probably come down and help.
Take your time and DO IT!
Keith
