Custom rear bumper

[MStudt]

Obviously start with the right tools, speed square, tape measure, grinder with cut off disc, grinding disc, a tiger disc (sanding disc) a chop saw or band saw, 6" magnetic level, pipe bender, drill press, writing chalk and the best of all a welder.

Now since your starting out, get a wire feed welder. Either MIG or Flux Core will do just fine.

A quick pro's and con's of each:

MIG welding is way cleaner and IMO easier, but its also requires more metal prep clean up, is more expensive, cant really weld outside very good if there is any wind, and has a big ass bulky gas bottle.

Flux Core welding is pretty much the opposite, it can weld out outside with no problem, requires less metal prep (even though the more prep, the better the weld with any process) doesn't need a gas bottle and is less expensive.

Which ever you go with, no one can ever get to much practice in welding, to much practice doesn't exist. So go buy a welding machine that your wallet can handle. Any Hobart, Miller (basically the same thing) or Lincoln wire feed welding machine MIG or Flux Core will be able to do the job better then you can.

Now that I got the "tools" out of the way, on to the learning how to weld part.

Practice, practice so more and keep on practicing. Look up Chucke2009 on youtube, he has really good advice and doesn't bore you while your watching. Also look at weldingtipsandtricks.com, a very good website to read on welding.

Find a way to try and "test" your weld strength at home, either some type of press machine or big hammer. You don't want your bumper to fall apart on the highway, so please make sure your welds are ready enough. And since your a beginner, don't just butt to pieces together that are anything over 3/16" thick and expect pull penetration, because more then likely it just wont happen. Learn to bevel your two pieces or set a small gap to fill in, or both if your good enough.

Any questions feel free to ask me, no I am not a professional welder (really don't think anyone is in every single process, simply because there is a endless amount of learning and practicing to do) but I have a very good amount of experience in welding (SMAW, TIG, MIG and now Im learning FCAW) and fabricating, as well as others on this site.

Good luck! :bigok:

Could have saved yourself a lot of time typing if you would have read the entire thread.:wink2:

 

[Bandit Runner]

Here's the link to my rear bumper build thread. Not sure how much it will help as it is a plate bumper, and you are doing a tube bumper. FWIW.

Bandit Runner's 3rd Gen Rear Bumper Build - YotaTech Forums

 

[IBallEngineer]

Here's the link to my rear bumper build thread. Not sure how much it will help as it is a plate bumper, and you are doing a tube bumper. FWIW.

]

Bandit, I was very impressed by your bumper mock up. I don't have the wood skills to do something like that, or maybe I just don't have the patience.

I may have missed it in your thread, but did you use .180 plate? Of all the bumpers I've built, I've not had to grind so much weld as you did, again, it's a patience thing with me. I pre bend as much as possible.

Love that you tied the wings in horizontally, I've only done that once but it is worth it on a trail rig.

 

[Kurtis]

I also built my own rear bumper with a swing out. It's pretty simple, low profile, and I've only got maybe $100 bucks worth of cut off wheels into it. Nothing great but it's saved my ass quite a few times. It's somewhere in my built thread

 

[Bandit Runner]

I may have missed it in your thread, but did you use .180 plate? Of all the bumpers I've built, I've not had to grind so much weld as you did, again, it's a patience thing with me. I pre bend as much as possible.

Love that you tied the wings in horizontally, I've only done that once but it is worth it on a trail rig.

I used 1/8" thick steel. I'll probably try to bend more instead of cutting each part out separately next time.