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

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

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

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

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802 hits | 70.09 KB | Posted: 10/17/04
See ya later

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Here is the Bronco with no bumper and the plastic air dam removed from under the grill

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I used a cutting wheel to score the back of the plate steel where I wanted to bend it

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

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678 hits | 67.42 KB | Posted: 10/17/04
After bending I welded the bends front and back

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642 hits | 64.6 KB | Posted: 10/17/04

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629 hits | 92.51 KB | Posted: 10/17/04
All welded up and ready for paint

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640 hits | 62.07 KB | Posted: 10/17/04
Painted

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Test fit

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

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678 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

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667 hits | 80.73 KB | Posted: 10/17/04
Here are the upper tubes tack welded on

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All tubes tack welded in place

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I then took the bumper off to complete the welding on the tubing

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600 hits | 60.51 KB | Posted: 10/23/04

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

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

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566 hits | 82.31 KB | Posted: 10/23/04
Hole for the WARN 8274

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637 hits | 79.95 KB | Posted: 10/23/04
Finish paint

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607 hits | 83.83 KB | Posted: 10/23/04

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699 hits | 84.78 KB | Posted: 10/23/04
On the truck and lookin sexy!

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

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603 hits | 81.94 KB | Posted: 10/27/04
Another view of the bottom