93-1BumperView.GIF
2106 hits | 9.14 KB | Posted: 10/5/12
This is the plan: a C8x11.5 (just like the previous one) with some 1/4" plate attached by squar...

93-2MockUp.JPG
1637 hits | 108.6 KB | Posted: 10/5/12
There's barely room for the trim & the fairlead, which will be partially hidden.

93-4Beam1.JPG
1692 hits | 95.09 KB | Posted: 10/5/12
This is how I start a bumper!

93-4Beam6.JPG
1578 hits | 91.28 KB | Posted: 10/5/12
A couple of cutting wheels later, and I have the core of the bumper.

93-5BeamDrill.JPG
1496 hits | 102.54 KB | Posted: 10/5/12
I'm really enjoying my new (used) drill press.

93-8Clearance.JPG
1521 hits | 92.77 KB | Posted: 11/24/12
Good thing I added an inch to the bumper mounts, or the gearbox would hit the core support.

[url=ht...

93-8Clearf.JPG
1446 hits | 61.11 KB | Posted: 12/19/12
One of the motor drive cover bolts is VERY close to the condenser bracket bolt on the core support. ...

93-8Top.JPG
1437 hits | 39.74 KB | Posted: 11/24/12
With the winch drum centered between the frame rails, there's barely a half inch between the motor &...

Shackles1.25.JPG
1438 hits | 119.84 KB | Posted: 10/11/11
I found these 1 1/4" (cross-section) shackles (galvanized cast iron) on sale at the Hot Springs...

Drawbars.JPG
1813 hits | 66.03 KB | Posted: 11/29/12
The bull nose gives these drawbars a finished look, and probably strengthens them slightly. I had p...

93-12Hook.JPG
1365 hits | 97.17 KB | Posted: 4/15/13
It's not welded in yet, but this bar will stow the cable hook and also be strong enough to use as a ...

93-12Hooked.JPG
1364 hits | 96.83 KB | Posted: 4/23/13
The hook storage bar is now fully welded-in, and the top front panel is going on tomorrow.

93-12Lbow.JPG
1340 hits | 62.08 KB | Posted: 4/23/13
Ouch - need T-shirts with SLIGHTLY longer sleeves.

93-12plate.JPG
1424 hits | 103.62 KB | Posted: 4/27/13
Scattered showers & a tornado warning kept me indoors most of the day, so I cut the front plates, an...

93-12Slotted.JPG
1296 hits | 87.3 KB | Posted: 4/27/13
The plating on the front face includes slots for this turbo-diesel (& high-trim) bumper pad. It wil...

93-12platet.JPG
1367 hits | 82.09 KB | Posted: 4/27/13
With the front plating & the structure that holds it in place, the center section of the bumper is n...

93-13PinStop.JPG
1491 hits | 82.05 KB | Posted: 5/24/13
This 3/8" chain link will not only prevent the shackle pin from coming out (while the draw bar ...

93-14Frontc.JPG
1284 hits | 67.01 KB | Posted: 6/30/13
The front plates are just tacked on while I fit & square everything.
IF THE IMAGE IS TOO SMALL, clic...

93-15Cnrs1.JPG
1299 hits | 87.74 KB | Posted: 7/29/13
I had this drop of 1/4" plate rolled into a 12" O.D. at a local fab shop.

93-15Cnrs2.JPG
1242 hits | 100.16 KB | Posted: 7/29/13
After laying out the angle of the front panels onto the curve, I cut the bumper corners out.

93-15Cnrs4.JPG
1181 hits | 96.96 KB | Posted: 7/29/13
It's coming together just the way I planned.

93-15Cnrs6.JPG
1324 hits | 86.43 KB | Posted: 7/29/13
The alignment looks perfect.

93-15Cnrs8.JPG
1417 hits | 83.55 KB | Posted: 7/29/13
After torching the curve into the upper angled strips, I tacked them all together & cut the angled c...

93-15Cnrs14.JPG
4068 hits | 84.4 KB | Posted: 7/30/13
It looks more complete than it actually is...
IF THE IMAGE IS TOO SMALL, click it.

93-16 Plasma.JPG
1528 hits | 56.47 KB | Posted: 8/13/13
I think these are all the parts I need to finish the front bumper, & replace a part I never liked on...

93-17A.JPG
1289 hits | 96.58 KB | Posted: 8/14/13
I hand-bent this 1" lip.

93-17D.JPG
1222 hits | 106.14 KB | Posted: 8/14/13
The outboard top panel (below the headlight) is just resting in place while I check its fit, and sev...

93-17B.JPG
1162 hits | 95.01 KB | Posted: 8/14/13
I spent a lot of time taking measurements before drawing these panels, but I was still surprised by ...

93-17Flap.JPG
1201 hits | 94.71 KB | Posted: 8/14/13
This will cover the winch, but it'll be easy to slide out, and it's strong enough to stand on.

[url...

Door New.JPG
1373 hits | 75.17 KB | Posted: 8/18/13
I was never happy with the previous door on this bumper, and I finally came up with a revised design...

93-17G.JPG
1128 hits | 39.28 KB | Posted: 8/18/13
I wish I hadn't cut so much off the curved ends - they don't reach back (up in the pic) far enough, ...

93-18 Cover.JPG
1328 hits | 71.57 KB | Posted: 8/23/13
This plate will cover the winch, but it can be pulled out for access, or to use as a step. I might ...

93-18Test Box.JPG
1144 hits | 65.28 KB | Posted: 8/26/13
Despite the complexity, and all the mistakes I made during fabrication, the first storage box & its ...

93-19FrRt.JPG
1399 hits | 124.95 KB | Posted: 8/27/13
It's looking pretty close to what I wanted. I just hope the other side comes out the same...

[url=...

93-20GuardStart.JPG
1172 hits | 96.83 KB | Posted: 9/5/13
The uprights for the grille guard are fabricated from 1/4" plate, and include internal latches ...

93-20GuardTwo.JPG
1199 hits | 114.55 KB | Posted: 9/7/13
I cut off the tack welds holding the R box together and added that grille guard mechanism. The tubi...

93-20GuareLeves.JPG
1150 hits | 113.68 KB | Posted: 9/8/13
This lever operates the latch at the bottom of the upright, inside the bumper, but I'm not happy wit...

93-21GuardBart.JPG
1286 hits | 105.83 KB | Posted: 9/10/13
Crossbars going in. It looks like the body might be ~1/16" low on the driver's side because th...

93-21Idiot.JPG
1517 hits | 129.08 KB | Posted: 9/19/13
Can you tell which welds were done with the gas hose pinched off?

93-21Joints.JPG
1247 hits | 125.03 KB | Posted: 9/21/13
It's taking a long time, and several skim passes in some places followed by a LOT of grinding, but t...

93-21LDoor.JPG
1107 hits | 106.61 KB | Posted: 9/22/13
I got the nerve up to start building the L door today, and I almost finished it. It fits at least a...

93-21Tether.JPG
1366 hits | 119.29 KB | Posted: 9/23/13
These storage compartment doors are heavy & difficult-to-build, so I don't want them falling off or ...

93-21Tethes.JPG
1169 hits | 128.29 KB | Posted: 9/24/13
These doors are heavy & difficult-to-build, so I don't want them falling off or getting misplaced.

93-21Y.JPG
1236 hits | 99.11 KB | Posted: 9/24/13
The front bumper doors fit so well & slide so easily that one fell off on this drive. I ran over it...

93-22Bar.JPG
1248 hits | 113 KB | Posted: 9/26/13
This went a lot faster than I expected - only about 4 hours including cleanup. I still may add a fl...

93-22Shackles.JPG
1315 hits | 103.95 KB | Posted: 9/30/13
I'm not really happy with these curves, but they're as good as I could do for now. They'll keep the ...

93-23Latched.JPG
1187 hits | 121.6 KB | Posted: 10/5/13
I was sweating these latches, but they came out at least as good as I expected. The door can be ins...

93-23Winch.JPG
1133 hits | 116.53 KB | Posted: 10/8/13
My thumb is still sore, but the winch is back in. I'll probably stress-test the whole thing later t...

93-24DivKpr.JPG
1306 hits | 133.12 KB | Posted: 3/12/14
I removed the torch-rolled shackle keepers and installed these bandsaw-cut pipe crescents, which loo...

93-26GuardTabs.jpg
1156 hits | 149.77 KB | Posted: 3/19/14
This leg will prevent the guard from being pushed back into the headlights. But the tab it fits ont...

93-27GGradii.jpg
1354 hits | 143.31 KB | Posted: 4/5/14
These became really complicated, but they turned out at least as well as I expected. Much better th...

93-27GGZ.JPG
2465 hits | 122.54 KB | Posted: 4/5/14
There are still a few internal things to do, but the outside is done. It came out pretty close to m...

93-28Paint01.JPG
1408 hits | 131.74 KB | Posted: 7/20/14
YEAH! That looks a LOT better!

I had a little mishap with an air compressor... It's a long story.

93-28Paint07.JPG
2083 hits | 122.85 KB | Posted: 7/20/14
Looking good, but I still want to sandblast & powdercoat the whole front bumper eventually.

[url=ht...

93-28Paint10.JPG
14267 hits | 123.25 KB | Posted: 7/20/14
Looking good, but I still want to sandblast & powdercoat the whole front bumper eventually.

[url=ht...

BrushGuard.JPG
1460 hits | 140.93 KB | Posted: 12/8/14
Yeah, the fold-down grille guard works. And it's at least as strong as I had hoped.

UPDATE: Turns ...

BumperMkIICAD.jpg
2225 hits | 116.17 KB | Posted: 1/11/15
A screenshot of the CAD drawing for the revised front bumper.
IF THE IMAGE IS TOO SMALL, click it.

...

Bumper83build.jpg
432 hits | 86.66 KB | Posted: 3/24/21
A solid bumper starts at the frame. A solid grill guard does, too.

[url=https://www.supermotors.net...