- Thread starter
- #41
Exhaust got cut off. The build is complete. Paint is currently drying and I will be doing the final install in the next hour or so. While I wait on the paint I will start posting pics.
Thoughts on my bumper design (1 Viewer)
- Thread starter bhicks
- Start date
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Exhaust got cut off. The build is complete. Paint is currently drying and I will be doing the final install in the next hour or so. While I wait on the paint I will start posting pics.
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- #42
Here's step one. I had to cut off the rear frame section with my sawzaw. I was a little uneasy cutting off that amount of frame. My fear was that the 80 would somehow twist or move in some way but everything stayed straight and true. I bolted the plates to the frame so I could see where I needed to further cut the frame around the plate. Once I cut the frame properly I then plated it in and tossed on some satin black rustoleum. You will see in the last pic how much the exhaust hangs down. that will be addressed later.
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- #43
Here's a pic of the plate re-installed after I boxed in the frame and painted it. I made sure the frame cleared the uppper and lower tube but still had enough left to give side support to the outer edge of the frame plate. You can also see the grade 8 bolts go through the frame right at the body mount. I figured that section was already reinforced and seemed to be the strongest part of the frame to run the bolts through.
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- #44
After multiple hours of playing with my harbor freight $80 pipe bender I finally felt confident to start bending the tubing. BTW I did a LOT of kinking pipe before I figured out a way to bend the pipe with zero kinks. I bent the two main pipes and then tacked them and the hitch all together. at this point I had not added any supports so the tubes are just hanging there.
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- #45
Once I got the tubes tacked on I was ready to add the supports around the hitch and the outer tubes. I did not have a tube notcher so I had to use a cut off wheel and grinder to notch the tubes. HOLY CRAAAAP!!!! that SUCKED!!! That took longer then any other step. I eventually got all the supports cut and tacked in. I then went to my buddies shop and used his big Lincoln welder to weld it all up. My little harbor freight FLUX mig welder was not gonna cut it. I did all the outer welding and he (a certified welder) welded up the hitch area. I didn't trust my limited practice welding with such a crucial part of the structural integrity of the design. I did not bring my camera so I don't have any pics of the welding. Once I got it home last night I grinded up some of the uglier welds. Almost all of those were the ones I did. I then cleaned it up with some acetone and went to bed. This morning I put a primer/paint all in one bottom coat on. Once that was dry I put two more thin coats of rustoluem satin black. This is now up to date. I will go out and install as soon as I finish this post. I will get pics up within an hour or two.
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- #46
I forgot to talk about the exhaust. I just ran down and snapped a couple pics of my solution. I did have to cut a large section of the exhaust off. The exhaut hanger which is on the outside of the frame had to be relocated to the inside of the frame. The metal straps that mount the exhaust to the hanger were reused. I simply rewelded them directly onto the muffler. This is definately not a great idea but with the limited space I had it seemed to be the only option. Well... at least the quickest and cheapest option.
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- #47
Here it is all installed. I weighed it and it came in at 67 lbs. The amount of stuff I cut away weighed 25 lbs. and the hitch was about 45 lbs. That is a total of 70 lbs. Which means I am currently 2 lbs. lighter then stock and WAY stronger. I am very happy with the overall final wieght. My goal was to keep my rig as light as possible. The last pic shows all the junk I cut off, which doesn't include the hitch since I already sold that.
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Nice job, looks nice and clean
Skilled!!!
Nice job, I really wish someone would offer this type of bumper up for sale. I can't find anyone that commercially makes a tube rear. And I don't possess the skills to fab one.
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- #53
I'm definately no fabricator. This was the first time I have ever bent tubing. I used my cheapo harbor freight bender and way cheapo harbor freight MIG flux welder. The tube bender took some practice and I did some serious kinking before I finally figured out how to bend the tube clean. The cheapo welder took a lot of practice before I got good enough to really get a clean bead. I still didn't use it in the end for the structural (hitch related) welding. You just have to try it and enjoy the learning process. I already am working on plans for the front bumper. That will have to wait until this summer when I have some vacation time again.
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- #55
Great job on the bumper! Clean, minimalistic, functional, lightweight, and looks good too!
Thanks. Guys I forgot to mention. A few of you mentioned wanting a set of the frame plates I used for the bumper. Max at Dirtbound offroad cut them out for me and said he is willing on cutting them out for anyone who wants a set. He wasn't sure on cost yet and we still need to make a couple changes to the design now that I have built and installed the bumper. He might put together a plate and hardware kit to get you started. You would need to provide the tubing and bender. It would just be a good starting point for your own creativity and fab work.
Slomo
It's Complicated
Nice work. 
It is always refreshing to see new ideas brought to life, that is a very good looking bumper, if flows well with the 80's design.
It is always refreshing to see new ideas brought to life, that is a very good looking bumper, if flows well with the 80's design.
I'm not a tube bumper guy but your design has me rethinking that. Nice work and design. I really like the simplicity of the design and how it makes the departure angle better nice job.
My only thought would be the tail pipe. Do you think it's far enough out so it won't build up exhaust gases under the car if you got stuck and had to run the engine to stay warm?
Just a thought
My only thought would be the tail pipe. Do you think it's far enough out so it won't build up exhaust gases under the car if you got stuck and had to run the engine to stay warm?
Just a thought
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- #58
Nice work.
It is always refreshing to see new ideas brought to life, that is a very good looking bumper, if flows well with the 80's design.
Thanks. Hopefully the front bumper I'm working on will turn out clean and flow well also.
I really like it! Nice work. Looking forward to your front bumper design.
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- #60
I tried to cut the exhaust out far enough past the frame and at an angle steep enough to push the exhaust gases down and away from the body. On a really cold morning you can see the steam from the exhaust blowing out below and away from the body. I'm pretty sure there isn't an issue there, but I guess time will tell.
