93-1BumperView.GIF
1957 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
1514 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
1563 hits | 95.09 KB | Posted: 10/5/12

This is how I start a bumper!
93-4Beam6.JPG
1458 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
1376 hits | 102.54 KB | Posted: 10/5/12

I'm really enjoying my new (used) drill press.
93-8Clearance.JPG
1406 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.

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93-8Clearf.JPG
1311 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
1313 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
1320 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
1665 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
1231 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
1230 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
1225 hits | 62.08 KB | Posted: 4/23/13

Ouch - need T-shirts with SLIGHTLY longer sleeves.
93-12plate.JPG
1302 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
1181 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
1240 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
1366 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
1165 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
1175 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
1126 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
1058 hits | 96.96 KB | Posted: 7/29/13

It's coming together just the way I planned.
93-15Cnrs6.JPG
1208 hits | 86.43 KB | Posted: 7/29/13

The alignment looks perfect.
93-15Cnrs8.JPG
1303 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
3950 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
1404 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
1164 hits | 96.58 KB | Posted: 8/14/13

I hand-bent this 1" lip.
93-17D.JPG
1098 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
1046 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
1082 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
1242 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
1024 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
1208 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
1036 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
1276 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...

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93-20GuardStart.JPG
1034 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
1088 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
1020 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
1161 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
1401 hits | 129.08 KB | Posted: 9/19/13

Can you tell which welds were done with the gas hose pinched off?
93-21Joints.JPG
1132 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
990 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
1248 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
1050 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
1119 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
1121 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
1191 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
1053 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
1009 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
1166 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
1034 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
1217 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
2328 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
1273 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
1946 hits | 122.85 KB | Posted: 7/20/14

Looking good, but I still want to sandblast & powdercoat the whole front bumper eventually.

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93-28Paint10.JPG
13871 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
1321 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
2008 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
274 hits | 86.66 KB | Posted: 3/24/21

A solid bumper starts at the frame. A solid grill guard does, too.

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