This is the plan: a C8x11.5 (just like the previous one) with some 1/4" plate attached by squar...
Hits: 1957
Size: 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...
There's barely room for the trim & the fairlead, which will be partially hidden.
Hits: 1514
Size: 108.6 KB
Posted: 10/5/12
There's barely room for the trim & the fairlead, which will be partially hidden.
This is how I start a bumper!
Hits: 1563
Size: 95.09 KB
Posted: 10/5/12
This is how I start a bumper!
A couple of cutting wheels later, and I have the core of the bumper.
Hits: 1458
Size: 91.28 KB
Posted: 10/5/12
A couple of cutting wheels later, and I have the core of the bumper.
I'm really enjoying my new (used) drill press.
Hits: 1376
Size: 102.54 KB
Posted: 10/5/12
I'm really enjoying my new (used) drill press.
Good thing I added an inch to the bumper mounts, or the gearbox would hit the core support.

[url=ht...
Hits: 1406
Size: 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. [url=ht...
One of the motor drive cover bolts is VERY close to the condenser bracket bolt on the core support. ...
Hits: 1311
Size: 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. ...
With the winch drum centered between the frame rails, there's barely a half inch between the motor &...
Hits: 1313
Size: 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 &...
I found these 1 1/4" (cross-section) shackles (galvanized cast iron) on sale at the Hot Springs...
Hits: 1320
Size: 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...
The bull nose gives these drawbars a finished look, and probably strengthens them slightly.  I had p...
Hits: 1665
Size: 66.03 KB
Posted: 11/29/12
The bull nose gives these drawbars a finished look, and probably strengthens them slightly. I had p...
It's not welded in yet, but this bar will stow the cable hook and also be strong enough to use as a ...
Hits: 1231
Size: 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 ...
The hook storage bar is now fully welded-in, and the top front panel is going on tomorrow.
Hits: 1230
Size: 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.
Ouch - need T-shirts with SLIGHTLY longer sleeves.
Hits: 1225
Size: 62.08 KB
Posted: 4/23/13
Ouch - need T-shirts with SLIGHTLY longer sleeves.
Scattered showers & a tornado warning kept me indoors most of the day, so I cut the front plates, an...
Hits: 1302
Size: 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...
The plating on the front face includes slots for this turbo-diesel (& high-trim) bumper pad.  It wil...
Hits: 1181
Size: 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...
With the front plating & the structure that holds it in place, the center section of the bumper is n...
Hits: 1240
Size: 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...
This 3/8" chain link will not only prevent the shackle pin from coming out (while the draw bar ...
Hits: 1366
Size: 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 ...
The front plates are just tacked on while I fit & square everything.
IF THE IMAGE IS TOO SMALL, clic...
Hits: 1165
Size: 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...
I had this drop of 1/4" plate rolled into a 12" O.D. at a local fab shop.
Hits: 1175
Size: 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.
After laying out the angle of the front panels onto the curve, I cut the bumper corners out.
Hits: 1126
Size: 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.
It's coming together just the way I planned.
Hits: 1058
Size: 96.96 KB
Posted: 7/29/13
It's coming together just the way I planned.
The alignment looks perfect.
Hits: 1208
Size: 86.43 KB
Posted: 7/29/13
The alignment looks perfect.
After torching the curve into the upper angled strips, I tacked them all together & cut the angled c...
Hits: 1303
Size: 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...
It looks more complete than it actually is...
IF THE IMAGE IS TOO SMALL, click it.
Hits: 3949
Size: 84.4 KB
Posted: 7/30/13
It looks more complete than it actually is... IF THE IMAGE IS TOO SMALL, click it.
I think these are all the parts I need to finish the front bumper, & replace a part I never liked on...
Hits: 1404
Size: 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...
I hand-bent this 1" lip.
Hits: 1164
Size: 96.58 KB
Posted: 8/14/13
I hand-bent this 1" lip.
The outboard top panel (below the headlight) is just resting in place while I check its fit, and sev...
Hits: 1098
Size: 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...
I spent a lot of time taking measurements before drawing these panels, but I was still surprised by ...
Hits: 1046
Size: 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 ...
This will cover the winch, but it'll be easy to slide out, and it's strong enough to stand on.

[url...
Hits: 1082
Size: 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...
I was never happy with the previous door on this bumper, and I finally came up with a revised design...
Hits: 1242
Size: 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...
I wish I hadn't cut so much off the curved ends - they don't reach back (up in the pic) far enough, ...
Hits: 1024
Size: 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, ...
This plate will cover the winch, but it can be pulled out for access, or to use as a step.  I might ...
Hits: 1208
Size: 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 ...
Despite the complexity, and all the mistakes I made during fabrication, the first storage box & its ...
Hits: 1035
Size: 65.28 KB
Posted: 8/26/13
Despite the complexity, and all the mistakes I made during fabrication, the first storage box & its ...
It's looking pretty close to what I wanted.  I just hope the other side comes out the same...

[url=...
Hits: 1276
Size: 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... [url=...
The uprights for the grille guard are fabricated from 1/4" plate, and include internal latches ...
Hits: 1034
Size: 96.83 KB
Posted: 9/5/13
The uprights for the grille guard are fabricated from 1/4" plate, and include internal latches ...
I cut off the tack welds holding the R box together and added that grille guard mechanism.  The tubi...
Hits: 1088
Size: 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...
This lever operates the latch at the bottom of the upright, inside the bumper, but I'm not happy wit...
Hits: 1020
Size: 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...
Crossbars going in.  It looks like the body might be ~1/16" low on the driver's side because th...
Hits: 1161
Size: 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...
Can you tell which welds were done with the gas hose pinched off?
Hits: 1401
Size: 129.08 KB
Posted: 9/19/13
Can you tell which welds were done with the gas hose pinched off?
It's taking a long time, and several skim passes in some places followed by a LOT of grinding, but t...
Hits: 1131
Size: 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...
I got the nerve up to start building the L door today, and I almost finished it.  It fits at least a...
Hits: 990
Size: 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...
These storage compartment doors are heavy & difficult-to-build, so I don't want them falling off or ...
Hits: 1248
Size: 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 ...
These doors are heavy & difficult-to-build, so I don't want them falling off or getting misplaced.
Hits: 1049
Size: 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.
The front bumper doors fit so well & slide so easily that one fell off on this drive.  I ran over it...
Hits: 1119
Size: 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...
This went a lot faster than I expected - only about 4 hours including cleanup.  I still may add a fl...
Hits: 1121
Size: 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...
I'm not really happy with these curves, but they're as good as I could do for now. They'll keep the ...
Hits: 1191
Size: 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 ...
I was sweating these latches, but they came out at least as good as I expected.  The door can be ins...
Hits: 1052
Size: 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...
My thumb is still sore, but the winch is back in.  I'll probably stress-test the whole thing later t...
Hits: 1008
Size: 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...
I removed the torch-rolled shackle keepers and installed these bandsaw-cut pipe crescents, which loo...
Hits: 1166
Size: 133.12 KB
Posted: 3/12/14
I removed the torch-rolled shackle keepers and installed these bandsaw-cut pipe crescents, which loo...
This leg will prevent the guard from being pushed back into the headlights.  But the tab it fits ont...
Hits: 1034
Size: 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...
These became really complicated, but they turned out at least as well as I expected.  Much better th...
Hits: 1217
Size: 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...
There are still a few internal things to do, but the outside is done.  It came out pretty close to m...
Hits: 2328
Size: 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...
YEAH!  That looks a LOT better!

I had a little mishap with an air compressor... It's a long story.
Hits: 1272
Size: 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.
Looking good, but I still want to sandblast & powdercoat the whole front bumper eventually.

[url=ht...
Hits: 1946
Size: 122.85 KB
Posted: 7/20/14
Looking good, but I still want to sandblast & powdercoat the whole front bumper eventually. [url=ht...
Looking good, but I still want to sandblast & powdercoat the whole front bumper eventually.

[url=ht...
Hits: 13871
Size: 123.25 KB
Posted: 7/20/14
Looking good, but I still want to sandblast & powdercoat the whole front bumper eventually. [url=ht...
Yeah, the fold-down grille guard works.  And it's at least as strong as I had hoped.

UPDATE: Turns ...
Hits: 1321
Size: 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 ...
A screenshot of the CAD drawing for the revised front bumper.
IF THE IMAGE IS TOO SMALL, click it.

...
Hits: 2007
Size: 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. ...
A solid bumper starts at the frame. A solid grill guard does, too.

[url=https://www.supermotors.net...
Hits: 274
Size: 86.66 KB
Posted: 3/24/21
A solid bumper starts at the frame. A solid grill guard does, too. [url=https://www.supermotors.net...
  

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