Purchased my 2nd Coastal Offroad bumper.
I'm trying to document the steps with pics.... here goes

It's best to build this bumper on vehicle for fit and alignment. The side wings needed angled to follow the body lines, see below.

I suggest buying your M12 bolts the manual calls for before hand. I also ran a tap in the holes as they are not normally used and therefore rusty usually.

Lay all your pieces out and number them per the manual.

Note the new design has the front plate, skid plate, and top plate all as one now.

Pic 1- after you remove bumper and cut factory supports fit plate 1 up and center it. Install nuts full tight.

Pic 2- ensure good clearance on A/C line, bend carefully as needed. Highly recommend putting rubber vacuum line over it to protect it. When the winch is on the cable/rope may rub on line and wear through it, rubber will prevent this.

Pic 3/4- bevel plates 2 and 3 so you have a good channel to weld them together. Then put a couple tacks to hold them together. I used a socket in shackle hole to help line them up.

Pic 5/6- highly suggest finding and buying the M12 bolts that are called for before you assemble bumper... I had to hit several lowes/home depots to find the uncommon thread pitch. Now fit part 2/3 up and align at top edges and tighten M12 bolt to hold in place.

Pic 7- ensure plate 4 fits between, it sits on top of parts 3 and part 1. Now tack parts 2/3 and part 4. Once it's all tacked remove it. Time to weld!

Pic 8- this is where part 4 sits on part 1. I did not bevel it and so I used a cutting disc to open seam for weld to fill.

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Next series

Pic 1- opened groove

Pic 2- all welded and grinded back down to be smooth

Pic 3- the inside area will be covered by the front/skid plate piece so go ahead and weld entire inner area. Make sure you weld the channel of parts 2 and 3 then grind smooth as the front plate will sit on this. Groove your edges on part 2 and the front plate assembly... I suggest setting the front plate on and marking where it needs beveled. You can see my bevel on Pic 6.

Pic 4- I suggest having your lights and doing these light tabs before installing front plate, it's hard to do them and level them when on. I installed pod to tab, held pod/tab in place and marked it.

Pic 5- I suggest only tacking for now so you can verify ights look right once bumper is done. Finish welding tabs at end of build. If they are just tacked you can tap them with a hammer and bend them some for even alignment.

Pic 6- front plate resting in place. I installed and welded this plate all off vehicle. Or you could tack with it installed. Your choice.

Pic 7- middle section complete

Pic 8- I like to cut out a spot to slide hand in to unlatch hood... yiu don't need it as you can go through front plate opening but it's a pain with winch installed. This makes it easy and you know right where latch is at.

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Use a grinder to smooth the opening out

I will post the next series of steps when I get to it.

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Wait, didn’t you already have a coastal bumper?


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Yup. Was my first welding project. I made some mistakes... I have since done lots of welding and learned alot. Got my own plasma and welder too. We did a local group buy so I got a new one and they did that custom tree cut out on front plate.

Welder

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Oh ok makes sense, I like the fog cutouts more than the square ones! I’ve been thinking about cutting off the wings and making them out of tube to make it a hybrid, we’ll see lol.


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Yeah. Someone has done that I've seen on their IG looks good too.

Are you planning on putting a winch in the bumper?

It is a pretty good look. Thats what I'm thinking about doing when the time comes

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Been thinking about doing that with mine as well. Should drop a little weight off it.

Precisely! If I wake up with a case of the **** arounds I might just cut the wings off tomorrow.

It was also my first welding project and it shows. I’m happy with the center section but the wings don’t line up with the fenders or “smile” the front end has due to lack of skill on my part. The gap gets worse towards the fenders and it bothers the crap out of me lol.


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Should help a bit, hadn’t even considered that!


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Yes. This is my 2nd CO kit

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Finally prepped the other pieces. Be sure to bevel where needed. Where parts 7 meet 16, bevel those edges that meet too.

Last pic is if you don't lift part 7 as you add each face piece, the end result will be a uneven gap. When I do mine I will take pics so it makes sense.

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