My 1983 SR5 Long Bed Build.

[dngspot]

Color scheme is still open. I am not happy with the finished result on the cab. I have a gallon of khaki that will be the finished coat. If that does not work out camo is the next step.
Bummer on the bumper. I can only hope mine works out.

 

[dngspot]

The winch plate is bolted in. I had to weld in a gusset to pick up a couple top bolts. The right one is in this pic the left one will be seen in the next.

I had to cut the tabs that are on the side of the weld plate. I could have cleaned up welds and left them in place. I could not use them because the bolts would have entered the box frame and I could not get a nut on them. The right gusset can be seen in this pick along with the cut off tab.

I drilled four holes through the front member. It was boxed also but four large drain holes were cut into it. I placed the winch plate on the member and drilled pilot holes through the member and plate. Then I took it apart and drilled 1/2 inch holes through the winch plate and member. I also welded up the holes that I am not using.

A view from the side.

 

[dngspot]

So far the winch plate is pretty strong. I used my high lift to pick up the front of the truck. No bending, cracking or separating. To build the bumper I thought it a good idea to mount the winch, in case of any of the plates making contact. I am glad I did, the winch would not fit with out trimming the grill. I took about an inch out of the bottom of the grill and in the winch went. I also had to drill out the fairlead holes in the winch plate.

 

[dngspot]

After work today I thought I would do something quick and simple, mock up the bumper. 4 hours later I think I am done. The material I am working with is a paper compound about 1/4 inch thick. The only way I could make a clean cut was with my small skill saw. Anyway the bumper is a copy of superman180's on pirate4x4 bumper. I found it on this sight and liked it.

 

[cody c]

After work today I thought I would do something quick and simple, mock up the bumper. 4 hours later I think I am done. The material I am working with is a paper compound about 1/4 inch thick. The only way I could make a clean cut was with my small skill saw. Anyway the bumper is a copy of superman180's on pirate4x4 bumper. I found it on this sight and liked it.

This truck looks good, I like the bumper its got a nice narrow profile, seeing it in a cardboard layout makes me think it would look good with paint to match the body color.

 

[dngspot]

Thanks Cody. Naw on the paint. It is going to be painted the same color as the grill.

Got the pieces cut and ground the edges. I traced the edges of the templates and cut them out with my plasma cutter.

 

[dngspot]

The plates are tacked in. Tomorrow I will remove the winch, then pull the winch plate/bumper off. Given enough time I will start welding it together.

 

[CreeperSleeper]

I'm diggin' that bumper!

 

[Sam Stewart]

I really like it too. Does it have any reinforcement other than the winch plate?

 

[dngspot]

Thanks guys. No additional reinforcement than the winch plate. The bumper is pretty ridged, when attached to the winch plate it kinda of gussets itself. The bumper is made of 3/16 plate steel and definitely stronger than the stock bumper.

I finished welding the bumper. I welded the front and ground the face. Then turned it over and welded the other side. This thing is pretty dang stout. I gave thought putting on a couple sheets of material on the back to box it in, but the thing is heavy enough with a winch, so no back.
I also am going to open up the fairlead hole in the winch plate. The fairlead mounting holes lower the fairlead and it is in the way for the receiver. This will come next. That thing is hotter than a two dollar, lady of the evening, on nickel night, so I am letting it cool before more work.
It is about 33 degrees, outside and the garage is closed up. This makes for a smoky pic.

 

[dngspot]

I cut the hole larger on the winch plate and raised the two fairlead mounting holes about 1.5 inches. Then I cut a 3/4 piece of 1/4 stock and butt welded it to the top of the winch plate above the fairlead opening. I then used my plasma to cut out the opening, about 1.25 inches from the top edge. I welded both sides of that 3/4 stock and ground both sides smooth. It is now ready for paint.
This is what it looks like now.

 

[dngspot]

The bumper is done and I am liking it.

 

[dngspot]

I finished the spare tire mount.
I cut a disk welded a couple pieces of 1.25 tube to it and welded in a long 1 inch bolt.

I welded a nut to the underside of the bed rails. Then drilled through the bolt and installed a theft deterrent device.

 

[dngspot]

More I look at the handles on the tire mount, the more I dislike it. I just think it looks a bit hokey. I will redo it when the truck it finished.
When I look at the truck it is the first thing I see, so it must go.

 

[GLTHFJ60]

What don't you like about it? I like it, it's unique.

 

[dngspot]

They look like insect antenna.

 

[SAWTOOTH 55 LC]

That front bumper and winch setup is Sweeeet!Nice work

 

[dngspot]

Thanks sawtooth

During the week I seemed to have so many others pulling at me to do work for them, I did not have much time for my stuff. My wife said I need to learn to say "no". She is so right.
I did manage to weld up a light bar during the week though.

A while ago a customer brought in a motor grader that was a burn victim. The tech that was working on the thing pulled off all of the lights and replaced them, as he was heading for the trash, I asked him what he had planned for them. Trash was his reply, mine was I will be happy to take care of that. The lights were covered in fire extinguisher spuge and the metal brackets and hardware started to oxidize.
I spent part of the day over a bucket full of soapy water, scrubbing the light housings. That did not help much, so I pulled, off of the shelf, a can of flat black pant and gave the housings and hardware a new coat. They look as good a new, if I don,t say so myself. As the paint dried I drilled the top tube of the bed and the light bar. Thank God for the Drill Doctor, the seem in the tube jacked up my bit, a couple times.
After the paint was dry, I simply assembled and installed the lights. A little more about the lights, they come new as 24v 70 watt halogen units. I simply removed the light bulbs and installed 12v 100 watt halogen bulbs.

The lights for the rear may be moved to the bar above them and mounted upside down. They stick out the rear of the bed a bit.

The next pic is from behind the top lights, it is easier to see the light bar. If you look closely you can see that I have already fished the wires.

And a front view. Four floods and two center spots.

 

[dngspot]

First coat is on

 

[jynx]

I am looking forward to seeing it all pulled out with the bumper, bed, spare mounted, tanks on, etc. The truck is going to be very nice. I know you are bound to be ready to get a little dirt on it.

The front bumper turned out really nice, BTW