Ideas on tube bumper repair?

[Spook50]

I have an older Smittybilt tube bumper on my 62 that I picked up for free a few years ago as an aesthetic improvement over my banged up factory bumper. One of the ends is fairly crunched in, and I'm at a loss in figuring out a good way to repair it effectively. I was able to bend it out somewhat using a large adjustable wrench, but obviously can't get it rounded enough to get a new cap in place. Hammer and large brass drift were ineffective, and I'm betting the steel (1/8" wall) is too thick for a tubing expander to work.

I'm suspecting my only option would be a short length of 3" OD DOM cut at an angle to beat into place and force the collapsed end outwards, but I'm open to ideas if anyone's fixed something like this before.

Here's what I'm looking at:

Don't mind the bees' nests inside the bumper. I didn't even realize those were there until I opened up the photo to edit it

 

[bj70bc]

cut off, weld in new

 

[Spook50]

cut off, weld in new

I considered that, actually. Not out of the question, but was hoping I could accomplish this without going that route.

I don't even think any of the steel suppliers near me are open during the weekends

 

[Eyedaho]

Looks tricky to get it back to round. I looked for a picture of one of these guys:

But then while looking for it I found this that looks like it might work too:

Obviously you don't want to spend a hundred bucks to fix a free bumper, but maybe someone you know has one. Sometimes you need to know what you're looking for before you can start looking!

 

[Spook50]

Looks tricky to get it back to round. I looked for a picture of one of these guys:
View attachment 3748069

But then while looking for it I found this that looks like it might work too:
View attachment 3748070

Obviously you don't want to spend a hundred bucks to fix a free bumper, but maybe someone you know has one. Sometimes you need to know what you're looking for before you can start looking!

Yeah this is a new one for me, given all my past pipe fitting work was on inconel (really soft stuff by comparison) or thin wall stainless that was also easy to manipulate.

I'm betting a flange spreader like in your second pic would do this trick, and I've got a couple buddies that just might have something like that....

 

[e9999]

have you tried heating it up red hot with a torch and then hammering it over a heavy steel pipe or steel rod held rigidly in place?

Coincidentally, I just did that (minus the torch) today, although with copper so a lot easier, no doubt.

 

[Eyedaho]

Alternatively, you may already have the tools you need? Or maybe a "friend" does?

*Sorry, couldn't resist.

 

[Spook50]

Alternatively, you may already have the tools you need? Or maybe a "friend" does?
View attachment 3748423


*Sorry, couldn't resist.

Oh so now you're my "friend", eh?



Don't forget the rubber sheets and the gerbils.....

 

[Eyedaho]

Oh so now you're my "friend", eh?



Don't forget the rubber sheets and the gerbils.....

Cheers!

 

[bj70bc]

 

[bj70bc]