so I decided to build a new front bumper

[obex26]

What no comments from the peanut gallery?

The last pic If you look at the end it is probably my most complex weld joint to date. it consists of about 5 seperate pieces... Top is angle bottom part is about 1 1/2 inch which I capped, the back arm is 2 1 1/2 pieces with a 45 degree joint....

 

[zombie]

That is looking pretty good so far. It just goes to show what you can do at home by yourself. Makes me want to go and get a welder and try it myself. I do think you should throw some paint on there though, even if it is just spraybomb tremclad black. Nice looking truck.

 

[gotmud?13]

i like it. what grade of bolts are you using? myself i would use grade 8 bolts as the winch can put some serious strain on the metal, and especially if the whole thing is only held together with 6 bolts. might i suggest that you throw a few more passes of welds onto the frame mounts? ie a triple pass t or a 7 pass layered t. also, throw a buffing wheel on your grinder and have at it, taking all the rust off, and then just spray bomb it. if no paint is applied, then it will rust and corrode very easily, and looks bad. great work so far,

 

[obex26]

All bolts are grade 8 classed at capacity of 10k lbs I think.. The base mount is not only welded to the front plate which is quarter inch but It is also bolted into the frame right under the core support used the factory holes. I have a few ideas for a light bar I am toying with so a few more days of exposure wont hurt besides I purchased all of this material last year and it has been exposed and this is what it looked like.

 

[GarageAlchemist]

wow, thats really cool, id be interested in a schematic of it if you made one.

 

[obex26]

wow, thats really cool, id be interested in a schematic of it if you made one.

Sorry no detailed schematic. I originally started with the winch mounting plate that came with the winch and chopped of 4 inches from each side. My slightly off squares are 1 1/2 inches. And the sides extend about 19 inches on both sides from there.

Oh yea as I mentioned about frying my winch. Well went to Harbor freight on Sat to exchange my winch. The catch 22 to their warranty is its one time use only and then you have to buy a new extended warranty. But for a 500 dollar investment 50 bucks for a new warranty is not too bad. Well at first I asked about upgrading and then decided I did not want to invest the additional 70 dollars. to go from a 9K to a 10K. So as I wandered around looking for more tools and crap that I did not need I finally came back and asked for them to bring up the winch. After about an hour of waiting they finally informed me that they were missing 4 9K lb winches from inventory so they offered to give me the 10K for the same price. As a bonus it comes with a roller fairlead. Which I also looked into picking up. So I got unpgraded and also the extra part I wanted.

I have to say I have been beating the crap out of harbor freight tools for a while first one I had an issue with and from someone who is in a retail business I thought the guy did great for customer service.

 

[shootmymime]

on those older trucks! home made shit is allways the best! great idea u got goin there dude!!!

 

[Alabama4Runner]

I think you're doing a great job but I'm just too lazy and for the money I thought the ARB was hard to beat.

 

[obex26]

Lets just say the winch itself weighs probably 2 times what my front bumper does. I will probably but the rear bumper on a diet as well. I am still toying around with how I want to run the light bar. It just seems incomplete at this moment...

 

[obex26]

So I decided to say F** the light bar option for now and just 16 gauge flat sheet the tops and sides...

 

[obex26]

I started with 2 pieces of 12 x 18 16 gauge sheets that I sharpied approximate dimensions. I decided to make it somewhat more even and with my lack of experience welding sheet to try and flush it to the best of my abilities.

 

[obex26]

The top and sides in mock up...

I welded from the inside to prevent as much warpage as possible like i said it was my first time welding thin steel...

Just resting on the front mount area..

I am glad that I made the bumper bolt on and the mount plate welded and bolted..

Makes it easier to work with..

 

[obex26]

 

[obex26]

And painted..

 

[obex26]

 

[obex26]

I am not chopping down the ends.. They are flush with the fenders. I think of it as side marker protectors. If the bumper wont fit the truck wont either.. I have replaced too many corner lenses and it gets old after a while especially at 30 bucks a pop..