Builds THE LESS MAD - MAD MAX BUILD

Discussion in '80-Series Tech' started by Rainen, Apr 21, 2016.

  1. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    BUMPER BUILDING


    So I started digging into building a front bumper. I have this issue where I pick up used Warn winches off of Craigslist whenever they come up. I typically just use them for ballast, so my shed doesn’t blow away. But I decided it might be time to put one of these to use. I had and 8274 that I tried to fit up front, but I couldn’t find a way to get it mounted as tight as I wanted without cutting up the grill and sheet metal, which I did contemplate. But in the end I decided to go with an M10000. Warn no longer make this winch. They call it the M12000. I know that there are a lot of companies out there now that make winches. I always stick to Warn, simply because you can still order parts for every winch they have ever made. Which I think is pretty cool, its also why I am not afraid to buy them used.


    So I started with positioning the winch. I wanted it nice in low and tucked up as close to the body as I could get it.


    started.jpg


    I started with a cardboard template to create the base plate the winch would mount to. I then transferred that to some 3/16” plate and off we go.


    template.jpg


    It did take me a while to get started. This was the first front plate that I started with, but I hated the look of it, just more for the scrap bin.

    Front bad.jpg

    With a little (or a lot) of back and forth it started to take shape. The first side is always the most time consuming, but once I had that done it started to come together.


    Half Front.jpg
     
    Ronny Grady likes this.
  2. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    The second side is fun, because big things happen fast.



    Final welding, and grinding, and welding and grinding. But it came together.

    Bump Weld.jpg

    Then slap a little paint on it, and it’s the cleanest thing on the truck, that won’t last long

    Bumppaint.jpg
     
  3. cody c

    cody c

    Messages:
    5,068
    Likes Received:
    394
    Joined:
    Feb 20, 2006
    Location:
    calgary
    The white bumper looks good!
     
  4. YMT

    YMT

    Messages:
    155
    Likes Received:
    45
    Joined:
    Mar 20, 2017
    Location:
    Groveland, CA
    That is a sweet bumper! More pictures please!
     
  5. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    HEATER BYPASS

    Well this just happened.

    Heaterbypass.jpg

    I am in the process of building sliders and I got a little carried away. Note to self take it easy with the plasma cutter. So it looks like I will be deleting the rear heater. I am going to figure out how to bypass the thing so I can drive it tomorrow. I am hoping I have enough spare hose lying around. I will post up more photos on the bumper as soon as I get this dealt with.
     
  6. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    MORE BUMPER
    A few more shots of the painted bumper . just cause
    Bumper 2.jpg Bumper Side.jpg Bumper Top.jpg
     
    mehbohdi likes this.
  7. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    ENOUGH HEAT???
    So I was able to come up with some 5/8" heater hose for the rear heater bypass. I went even further and removed all the piping that goes from the engine compartment back to the heater. Not sure why I really thought this was a good idea at the time. But once I go into it it became obvious that those hard lines are put in first. Before the engine, transmission and exhaust go in. There is really no way to get them out unless of course you take them out in little pieces with a sawzall. Which is what I did. Even after all that though I am left with a small chunk on top of the cats. I think the only way to get these unbolted without removing the cat and the heat shield might be to just go through the floor. We'll save that for some other time.

    My question is though does anyone really use the rear heater? I am in Colorado, and granted I haven't driven this thing a ton in the winter, but the truck seem plenty warm without it. Just curious if anyone has removed it an regretted in later.
     
  8. JaketheSSnake

    JaketheSSnake SILVER Star

    Messages:
    794
    Media:
    32
    Albums:
    3
    Likes Received:
    861
    Joined:
    Dec 25, 2015
    Location:
    Iowa
    With a recently flushed and mostly new coolant system, mine gets stupid hot up front to where I don't think it's too bad in back. I need to run some thermometers back there when it gets below zero just to see what it's like. I don't miss it, but I basically bypassed it before I got to drive it in the winter lol.
     
  9. RFB

    RFB 97 FZJ80 LIFTED SC DUAL BATTERIES,37s GOLD Star

    Messages:
    2,502
    Media:
    8
    Likes Received:
    2,716
    Joined:
    Mar 7, 2017
    Location:
    Nahant Ma.
    I used all HPS hoses on my rig except on the PHH i used gates green stripe from Joey. I hear there are silicone hose issues. Ill keep all posted .
     
  10. scottryana

    scottryana

    Messages:
    9,985
    Media:
    1
    Albums:
    2
    Likes Received:
    7,195
    Joined:
    Feb 2, 2004
    Location:
    Salt Lake City, UT
    This is funny, I actually went through McMaster and made a parts list to make a better awning. Glad to see I am not the only one with the sickness. lol.

     
  11. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    JUST A LITTLE OF THE BOTTOM


    Ok so I prior to building the sliders I wanted to do some trimming on the body to keep things nice and tight. This wasn’t without incident, see previous picture. Trimming the body is a pain ended up using like every cutting tool I could find, plasma cutter, airsaw, Sawzall, grinders, tin snips you name it. So after getting it all cut, I started on capping the giant mud collecting hole I had made in the body.

    I started with 1/2” square tubing and some 14 gauge.

    CAPIMAGE.jpg

    And then some more trimming/scribing to get to match the body


    SCRIBED.jpg



    Then clamped up and welded to the body


    CAPCLAMP.jpg

    After getting these welded up I slathered it all with undercoating and started on the sliders


    CAPWELD.jpg
     
    mudgudgeon likes this.
  12. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    SLIDING 1


    For the sliders I decided to go with 2x6 rectangular tubing and 2” round tubing for the outside. I want to use at least one of these as a tank for compressed air.

    I started with the driver side, the easy side.


    CONSTRUCTION.jpg


    I tied the round and rectangular tubing together with 1/8” plate with dimple dies. I Placed these along the length


    MOCKUP.jpg


    I added a threaded bung to be able to pressurize the rectangular tubing.


    BUNG.jpg


    And pressure test


    PRESSURE.jpg
     
    mudgudgeon and GW Nugget like this.
  13. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    SLIDING 2


    After completing the driver side it was off the passenger side which was made more difficult by the cat on the outside of the frame. The rear two mounts were identical to the driver side. The front mount needed to incorporate at skidplate for the CAT that was removable in case I ever needed to replace it.

    After a couple intterations, I came up with two mounting points on the slider and one mounting point on the frame. The whole skid plate is cut from 3/8” plate and the mounting points are braced pretty well.


    I started with something like this


    SKID1.jpg


    Its difficult to get good photos of the mounting points under the truck, this is it sitting in place.


    SKID2.jpg


    In the end I didn’t like how exposed it left the side of the cat so I modified to have a more solid side. So the final ended up looking like this


    SKID 3.jpg


    And the pair of sliders complete and ready to go to powdercoat!!!


    SLIDERS.jpg
     
  14. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    REAR BUMPER 1


    So at long last it was time to move on to the rear bumper. And as always. We start with a little destruction. Pulling off the stock bumper and cutter the rear frame crossmember out of the way, as well as trimming the body.


    BODYTRIM.jpg


    After that I struggled with it a bit on how to get started, but in the end came up with this as a replacement for the cross member, this will also function as the hitch and the base of the bumper that will get skinned.

    BUMPBASE2.jpg

    This will be a dual swing out bumper, so the top is skinned and the hinge points placed and tacked to check fit.


    BUMPHINGE.jpg


    I then added tubing extended forward from the bumper to act as sliders. It also really tied the room together


    BUMPSLIDE.jpg
     
    2fpower, gofast and GW Nugget like this.
  15. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    REAR BUMPER 2


    “Just because you can doesn’t mean you should” – Someone a lot smarter than me.

    I have tendency to get carried away on project like this and make them more complicated than I should, or need to. While it is fun to stretch the limits of what I can build in a small shop, or to assemble things in a way I never have before, it becomes very time consuming. But the little details also make it fun


    DETAIL1.jpg


    DETAIL2.jpg


    In addition to selecting the hinges I did in order to have removable swings arms, I also wanted a single latch to hold it all together. Time, and some bumpy ass roads, will tell if this is a good idea or not.




    In addition to the spare tire I wanted to carry a single ammo can on the back for recovery gear. I did this on the last rig as well. I found being able to get to this gear quickly without have to dig or open anything made using it a lot easier. And here it is, 6 weeks of work condensed in a few photos.


    REAR1.jpg


    REAR2.jpg


    All I have to say is, I will never again question why rear, swing out bumpers cost so much money. And in the future I would will likely just pay the damn money!!!
     
    Last edited: Jun 8, 2018
  16. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    POWDER COAT!!!!


    I got the first pieces back from powder coat, and mounted up. I am going to change the color of the truck, so at some point the color scheme will make more sense.


    Powder1.jpg

    Powder2.jpg
    powdern3.jpg
    powder4.jpg
     
  17. GW Nugget

    GW Nugget There's nothing funnier thn dyslexic perfectionist

    Messages:
    2,782
    Media:
    7
    Albums:
    1
    Likes Received:
    2,487
    Joined:
    Jul 25, 2014
    Location:
    Coalinga, CA
    Heck Yeah, Armor up Baby? Nice.
     
  18. mudgudgeon

    mudgudgeon

    Messages:
    3,126
    Likes Received:
    1,938
    Joined:
    Dec 17, 2007
    Location:
    Sydney, Australia
    Are we related? :lol:

    Love your work.
     
  19. Outsane

    Outsane

    Messages:
    278
    Media:
    1
    Likes Received:
    340
    Joined:
    Oct 1, 2010
    Great thread
     
  20. Rainen

    Rainen SILVER Star

    Messages:
    77
    Likes Received:
    116
    Joined:
    Sep 8, 2015
    Location:
    Colorado
    Thanks

    Thanks
     
  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.