Tubular Front Bumper Design and Build (1 Viewer)

[SHAGGY101]

After finishing my rear bumper project I needed to balance out the front end with something that was more heavy than my tupperware up front and some thing that also looked better. After studying many other bumper designs and seeing things that I did and did not like and using my design requirements I came up with a final design.

As far as design requirements went, I wanted to have a full tubular structure for strength and maximum clearance. However, I also needed to cover/ protect all of the unsightly structure and components underneath. As a result, I went with a hybrid design. I also had to be able to tuck my Titan winch up as high and as tight to the grille as possible. My recovery points had to be attached in some way to the frame mounts. For lighting, I wanted to install a 30" light bar as well as 2 duallys. I also wanted to install 2 auxiliary flashers (thanks Loud) to let people know when I am changing lanes.

This is the initial design that I came up with after meticulously measuring the body, frame and frontal components of the vehicle. The frame mounts are made of 3/8" steel and the recovery points are 1" plate for side loads and less shackle movement. The tubes that attach the tubular bumper body attaches to the frame mounts are 1.5" x .25" DOM tube (overkill but I had it around and wanted to minimize deflection). The bumper body is made of 1.5" x 11ga tube. All of the plating between the tubes and the tabs are made of 3/16" plate. The winch cradle was made from 1.5" x 11ga square tube and the winch plate is 3/8" plate. Most of the materials chosen are much larger and thicker than they needed to be. Some of this had to do with the fact that that was the material I had on hand and the fact that I needed to add some meat to this bumper to offset the weight in the rear when loaded up for a long weekend.

front detail

side profile

 

[bluecruiser]

Nice.........can't wait to see the real version...

 

[SHAGGY101]

Design Revisions

After I completed the original design, I consulted with others (Loud, friends, and wife) and tried different frontal plate designs while still keeping the overall structure the same. In the end I think I got the most aesthetically pleasing (to me) design I could.

Which one do you like?

original circles

ovals

slots

slots

and more slots

looks a little like vegas?

looks like a cat?

a little more variation... (look at the bottom)

And the winner is...

According to Loud, "this one screams that this guy knows what he is doing and has some sweet tools." Do you?

 

[SHAGGY101]

Build time!

Now that I had my design solid, I could start cutting and bending everything with confidence in that fact that I was going to get most everything right the first time.

I first had to remove the factory bumper that had been mangled from past trips. There were no plastic clips holing on the plastic cover so it came off pretty easily. I then had to remove the frame end caps that are used to attach the stock bumper. Sorry, no pics but you can go look at slee's website and how to install the blueberry bumper if you are curious.

I then started on the frame mounts. Since my frame mounts would add holes to the frame I had to create some sort of template. In order to accomplish this, I cut all my pieces on a waterjet and attaced them to the frame. The pieces that already had existing holes and captured nuts were bolted on while the others that needed holes drilled and nuts welded onto the frame were clamped to be marked and drilled.

This is the end result after everything was drilled and welded into the frame

welded nut detail

front capped off with drain holes

These are my new FRBs...

all welded up and ready to go!

 

[SHAGGY101]

Build Continued

Now that the frame mounts were done, I had to make the tubular body of the bumper.

I first started by bending up the top most portion of the bumper and then the lower portion that has the compound plane bends. These were a little tricky to get right but after studying my solidworks (CAD) model and a test bend, I was ready to do the real thing. I then spot welded the two parts together along with some cross members.

I then fit the tube structure to the body. After I got everything lined up where I wanted it, I welded tube from the tubular body to the frame mounts.

In order to fit the support on the driver side I had to cut back some of the cover over the washer bottle.

All of the supports from the frame mounts to the tubular body are gusseted. Some are gusseted in 2 dimensions where needed.

I made sure the winch fit into the little space I left for it and checked to see if I needed to trim anything back

Turned out I had to cut off the little tab that held on the old bumper

I also had to bend back the little tabs under the headlights to clear the tube as well.

 

[SHAGGY101]

Sticking it all together

After getting everything fitted on the truck, I then welded on all of the finishing touches.

Putting on the plates

welding on some light tabs for some duallys. I made sure that none of the lights protruded past the tubular structure so that the possibility of damage was minimized.

Some blinker mounts

I welded up the winch plate and winch cradle. I ensured that the fairlead would not protrude past the central plate and get scraped up.

The final piece of the bumper I welded up was the light hoop. The 30" RI light bar I wanted was a tight fit but I got it to work. I used my own weld on tabs to mount the bar to the specific height I wanted it.

This thing puts out an OVERWHELMING amount of light!

 

[SHAGGY101]

Now that I had everything all welded up, I was ready for some paint!

My weapon of choice for this bumper was duplicolor graphite metallic wheel paint that I had used for all of the other armor and wheels on my vehicle. Before started painting, I had to do some prep work. I first started by wire brushing all of the rusty areas as well as the weld seams. I also had to chip off some spatter around some of the welds. I then wiped everything down with acetone to clean off any oils or other residues.

To paint, I first started off with duplicolor's self etching primer. This is a pretty powerful primer that also has some filler in it. It goes on thick and hides some of the imperfections in the tubes like scratches and stuff. After 2 or 3 coats I moved to the wheel paint. I then applied 3 coats to the bumper as well.

After letting it dry for a few days, I assembled everything onto the bumper since it would be such a tight fit once on the truck.

Before I installed everything, I wired in all of my lights. Since my truck is white i also decided to paint the portions under the fender lip graphite as well.

before

after
I cleaned up some of the wires and routing. You can see the RI light bar harness that I modified in the center of the frame.

I then shoe horned it onto the front of my truck with some hydraulic help.

 

[SHAGGY101]

Finished pictures

looking at the winch through the side

looking between the grille and radiator

blinker

 

[kashmir]

Wow - looks like great fun to be able to make your vision happen like that.

I actually liked that "LandCruiser" cut out at the bottom... Can't wait to see finished pics...

Newb question for you - do you treat the frame after the work you did or is rust a risk you just have to deal with later?

I guess the monster energy drinks are getting you across the finish line

 

[petrotk40]

oh hellz ya. I second the Land Cruiser cut out

 

[alexinWC]

The design looks great! I can't wait to see the finished product

 

[SHAGGY101]

The design looks great! I can't wait to see the finished product

It has been done for about a month now, just getting around to the writeup.

I liked the lc on the bottom as well but structurally, it would not have worked. If I took a direct hit on that panel the lettering would cave in whereas simple circles or slots would not. Function over form I guess.

 

[SHAGGY101]

Newb question for you - do you treat the frame after the work you did or is rust a risk you just have to deal with later?

I guess the monster energy drinks are getting you across the finish line

Yeah, monster and coffee were my drink of choice as a cadet. I guess not much has changed.

I did paint the inside of the frame as much as I could as well as the outside. It is an issue but not one I feel that will ever become a problem.

 

[FlammableFishie]

Shaggy, this bumper is killer! So impressed with the metalworking skills, can I buy that from you (not really, just jealous!)

 

[DallasFJ40]

Is it just me, or can others see the finished pictures?

 

[SHAGGY101]

Is it just me, or can others see the finished pictures?

I am still working on the thread when I get/ make time. I will post all of the finished pics tomorrow.

 

[SHAGGY101]

Just finished posting all of the pictures. Let me know if you guys have any questions or want any pictures of something specific.

 

[petrotk40]

umm, ya I want one of those. Are you thinking of selling your design to a fab shop?

 

[Reno]

That is awesome man looks great! I love the detail and thought process you put into it. I more or less have a question about solidworks if you dont mind. What version are you using and how did you learn to use it and to scale? Was it fairly easy? (something you can teach yourself?) I recently got an employee discount on the software and want to make the purchase. Thanks in advance, and can't say it enough but great work!

 

[Fitzgerald]

Man, that's one rugged looking 100. Very cool!