99' Hybrid Bumper Build

[genmarks]

99' Custom Hybrid Bumper Build

I was recently backed into by a friend, not too much damage but my fender and bumper were pretty bent. I just ordered a new fender and installed that
but for a bumper to be shipped out here to hawaii would cost 4x the bumper price, so I opted to make one with my dad which would be cheaper and why
would I not want to build one.

After a lot of research my goal was to have a functional and lightweight bumper, so my plan was to make it out of aluminum, I know it wont
completely protect me from rock crawling, but that is not my priority.
Damage:


Started by making aluminum brackets to weld to, this will allow the bumper to be removable

We rolled all the pipe right here in my garage. Here is the main top cross bar - welded on



Any tight bends that were to sharp for the roller we bent using a hand hydraulic pump pipe bender

 

[genmarks]

welded braces to the brackets

Frame all finished

Went on to add aluminum plate, we made templates out of cardboard


One side all tacked up

Got a couple circular turn signals at a local truck shop - drilled holes and installed them into the 2 side plates


Got them all wired

 

[genmarks]

Middle Plate cut out

All the major work is finished


I know it kinda looks like swiss cheese right now with all the holes, but I am gonna paint it black within the next week to match the car and not
stick out and be so flashy. Ill keep this thread updated once I get the paint on, comments welcome, thanks

 

[MStudt]

YES! I've been waiting for someone to build a bumper from aluminum. I'm working on ideas for my own bumper, and I'm still back and forth on aluminum for it. It looks good, and I can't wait to see the finished product.

 

[genmarks]

YES! I've been waiting for someone to build a bumper from aluminum. I'm working on ideas for my own bumper, and I'm still back and forth on aluminum for it. It looks good, and I can't wait to see the finished product.

haha Thanks! It is no heavier than the stock bumper but super solid, it won't budge! thanks I cant wait to see it finished as well, means a lot!

 

[Bandit Runner]

Looks good.

I need to learn how to weld aluminum!

 

[TCMach]

Not quite my style but damn it looks good! Really nice job with the curved panels.

 

[Chuckles89]

Looks sweet!

 

[fblainen11]

Looks very good! Fill the holes with a bunch of fog lights!!!

 

[4-Ripcord]

Just trim the mounting plates and you will be all set. Good work!

 

[genmarks]

Looks very good! Fill the holes with a bunch of fog lights!!!

Haha I was definitely considering filling in a couple fog lights! Im not sure how I feel about all the corner holes, I might fill in a couple of them, but I think I am gonna paint it first to see if they are very noticeable.

 

[genmarks]

Just trim the mounting plates and you will be all set. Good work!

The mounting plates are actually trimmed to the size of the edge of the frame, otherwise I would, I think once its black it won't be as noticeable.

 

[Whitson Metalworks]

I dig it! I want a tube roller bad!

 

[MandAtaco]

Well done, I love the aluminum! I'm extremely jealous of your roller, I've been eye balling a couple cheap ones just for stuff like that. Then I need a spool gun for my welder so I can weld aluminum!

Looks really nice! Whats it weigh?

 

[ggordon1971]

Nice job!

 

[fourfive]

Respect the creativity. I'm liking it, good work

 

[genmarks]

Well done, I love the aluminum! I'm extremely jealous of your roller, I've been eye balling a couple cheap ones just for stuff like that. Then I need a spool gun for my welder so I can weld aluminum!

Looks really nice! Whats it weigh?

Thanks, really appreciate it! believe it or not it weighs only 29 lbs! I had to use 2 scales because I didn't believe the first, but for how light it is, it is extremely solid and doesn't budge at all once bolted on

 

[genmarks]

Finished Product!

Gave it an acid wash and light sand to prep it for the primer and paint.
a couple coats of primer & paint and here it is.
Looks much better in my opinion! I am extremely happy with the result, no more bent bumper!

 

[Predatorhouse]

Think about putting bed liner on it so it matches your fender flares. other than that I jealous, dad's are awesome.

 

[Park]

Wow good looking. The gloss black really makes it pop! I wonder if you could build an aluminium bumper strong enough to handle a winch.