DSCN0091.JPG
543 hits | 75.26 KB | Posted: 10/17/04
This is what it looked like when I bought the Bronco

beforethefest2.JPG
578 hits | 103.51 KB | Posted: 10/17/04
Here it is ready for our first Broncofest in 2003

IMG_1342.JPG
597 hits | 83.52 KB | Posted: 10/17/04
This is what it looked like when I began this project

DSCN3201.JPG
557 hits | 69.73 KB | Posted: 10/17/04
1/4" x 8" plate steel for the new bumper

DSCN3204.JPG
718 hits | 70.09 KB | Posted: 10/17/04
See ya later

DSCN3205.JPG
3423 hits | 94.2 KB | Posted: 10/17/04
Here is the Bronco with no bumper and the plastic air dam removed from under the grill

DSCN3206.JPG
751 hits | 80.92 KB | Posted: 10/17/04
I used a cutting wheel to score the back of the plate steel where I wanted to bend it

DSCN3208.JPG
612 hits | 77.43 KB | Posted: 10/17/04
I then bent it to match the shape I had drawn on my workbench

DSCN3209.JPG
600 hits | 67.42 KB | Posted: 10/17/04
After bending I welded the bends front and back

DSCN3210.JPG
576 hits | 64.6 KB | Posted: 10/17/04

DSCN3212.JPG
552 hits | 92.51 KB | Posted: 10/17/04
All welded up and ready for paint

DSCN3213.JPG
575 hits | 62.07 KB | Posted: 10/17/04
Painted

DSCN3214.JPG
665 hits | 96.26 KB | Posted: 10/17/04
Test fit

DSCN3215.JPG
609 hits | 83.26 KB | Posted: 10/17/04
It fit just as planned
(better to be lucky than good!)

DSCN3216.JPG
606 hits | 66.42 KB | Posted: 10/17/04
I drilled it for 3 grade 8 bolts on each frame horn, these are temporary for now

DSCN3218.JPG
591 hits | 80.73 KB | Posted: 10/17/04
Here are the upper tubes tack welded on

DSCN3219.JPG
564 hits | 63.49 KB | Posted: 10/17/04

DSCN3223.JPG
586 hits | 55.38 KB | Posted: 10/17/04

DSCN3224.JPG
586 hits | 68.78 KB | Posted: 10/17/04
All tubes tack welded in place

DSCN3226.JPG
562 hits | 51.28 KB | Posted: 10/17/04
I then took the bumper off to complete the welding on the tubing

DSCN3228.JPG
525 hits | 60.51 KB | Posted: 10/23/04

DSCN3229.JPG
549 hits | 68.95 KB | Posted: 10/23/04
I welded and grinded alot from this point to get it to look decent

DSCN3241.JPG
519 hits | 75.49 KB | Posted: 10/23/04
This is how it ended up with a coat of paint

DSCN3249.JPG
496 hits | 82.31 KB | Posted: 10/23/04
Hole for the WARN 8274

DSCN3250.JPG
562 hits | 79.95 KB | Posted: 10/23/04
Finish paint

DSCN3285.JPG
524 hits | 83.83 KB | Posted: 10/23/04

DSCN3287.JPG
629 hits | 84.78 KB | Posted: 10/23/04
On the truck and lookin sexy!

DSCN3321.JPG
569 hits | 67.48 KB | Posted: 10/27/04
On the advice of a couple of friends, I added a bottom for strength

DSCN3324.JPG
536 hits | 81.94 KB | Posted: 10/27/04
Another view of the bottom