Steve83 > 1983 Ford Bronco > open folder Front Bumper Mk.2

This is the plan: a C8x11.5 (just like the previous one) with some 1/4" plate attached by squar...
93-1BumperView.GIF
2106 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...
There's barely room for the trim & the fairlead, which will be partially hidden.
93-2MockUp.JPG
1637 hits | 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!
93-4Beam1.JPG
1692 hits | 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.
93-4Beam6.JPG
1578 hits | 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.
93-5BeamDrill.JPG
1496 hits | 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...
93-8Clearance.JPG
1521 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.

[url=ht...
One of the motor drive cover bolts is VERY close to the condenser bracket bolt on the core support. ...
93-8Clearf.JPG
1446 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. ...
With the winch drum centered between the frame rails, there's barely a half inch between the motor &...
93-8Top.JPG
1437 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 &...
I found these 1 1/4" (cross-section) shackles (galvanized cast iron) on sale at the Hot Springs...
Shackles1.25.JPG
1438 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...
The bull nose gives these drawbars a finished look, and probably strengthens them slightly. I had p...
Drawbars.JPG
1813 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...
It's not welded in yet, but this bar will stow the cable hook and also be strong enough to use as a ...
93-12Hook.JPG
1365 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 ...
The hook storage bar is now fully welded-in, and the top front panel is going on tomorrow.
93-12Hooked.JPG
1364 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.
Ouch - need T-shirts with SLIGHTLY longer sleeves.
93-12Lbow.JPG
1340 hits | 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...
93-12plate.JPG
1424 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...
The plating on the front face includes slots for this turbo-diesel (& high-trim) bumper pad. It wil...
93-12Slotted.JPG
1296 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...
With the front plating & the structure that holds it in place, the center section of the bumper is n...
93-12platet.JPG
1367 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...
This 3/8" chain link will not only prevent the shackle pin from coming out (while the draw bar ...
93-13PinStop.JPG
1491 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 ...
The front plates are just tacked on while I fit & square everything.IF THE IMAGE IS TOO SMALL, clic...
93-14Frontc.JPG
1284 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...
I had this drop of 1/4" plate rolled into a 12" O.D. at a local fab shop.
93-15Cnrs1.JPG
1299 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.
After laying out the angle of the front panels onto the curve, I cut the bumper corners out.
93-15Cnrs2.JPG
1242 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.
It's coming together just the way I planned.
93-15Cnrs4.JPG
1181 hits | 96.96 KB | Posted: 7/29/13
It's coming together just the way I planned.
The alignment looks perfect.
93-15Cnrs6.JPG
1324 hits | 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...
93-15Cnrs8.JPG
1417 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...
It looks more complete than it actually is...IF THE IMAGE IS TOO SMALL, click it.
93-15Cnrs14.JPG
4068 hits | 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...
93-16 Plasma.JPG
1528 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...
I hand-bent this 1" lip.
93-17A.JPG
1289 hits | 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...
93-17D.JPG
1222 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...
I spent a lot of time taking measurements before drawing these panels, but I was still surprised by ...
93-17B.JPG
1162 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 ...
This will cover the winch, but it'll be easy to slide out, and it's strong enough to stand on.[url...
93-17Flap.JPG
1201 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...
I was never happy with the previous door on this bumper, and I finally came up with a revised design...
Door New.JPG
1373 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...
I wish I hadn't cut so much off the curved ends - they don't reach back (up in the pic) far enough, ...
93-17G.JPG
1128 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, ...
This plate will cover the winch, but it can be pulled out for access, or to use as a step. I might ...
93-18 Cover.JPG
1328 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 ...
Despite the complexity, and all the mistakes I made during fabrication, the first storage box & its ...
93-18Test Box.JPG
1144 hits | 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=...
93-19FrRt.JPG
1399 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...

[url=...
The uprights for the grille guard are fabricated from 1/4" plate, and include internal latches ...
93-20GuardStart.JPG
1172 hits | 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...
93-20GuardTwo.JPG
1199 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...
This lever operates the latch at the bottom of the upright, inside the bumper, but I'm not happy wit...
93-20GuareLeves.JPG
1150 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...
Crossbars going in. It looks like the body might be ~1/16" low on the driver's side because th...
93-21GuardBart.JPG
1286 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...
Can you tell which welds were done with the gas hose pinched off?
93-21Idiot.JPG
1517 hits | 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...
93-21Joints.JPG
1247 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...
I got the nerve up to start building the L door today, and I almost finished it. It fits at least a...
93-21LDoor.JPG
1107 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...
These storage compartment doors are heavy & difficult-to-build, so I don't want them falling off or ...
93-21Tether.JPG
1366 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 ...
These doors are heavy & difficult-to-build, so I don't want them falling off or getting misplaced.
93-21Tethes.JPG
1169 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.
The front bumper doors fit so well & slide so easily that one fell off on this drive. I ran over it...
93-21Y.JPG
1236 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...
This went a lot faster than I expected - only about 4 hours including cleanup. I still may add a fl...
93-22Bar.JPG
1248 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...
I'm not really happy with these curves, but they're as good as I could do for now. They'll keep the ...
93-22Shackles.JPG
1315 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 ...
I was sweating these latches, but they came out at least as good as I expected. The door can be ins...
93-23Latched.JPG
1187 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...
My thumb is still sore, but the winch is back in. I'll probably stress-test the whole thing later t...
93-23Winch.JPG
1133 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...
I removed the torch-rolled shackle keepers and installed these bandsaw-cut pipe crescents, which loo...
93-24DivKpr.JPG
1306 hits | 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...
93-26GuardTabs.jpg
1156 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...
These became really complicated, but they turned out at least as well as I expected. Much better th...
93-27GGradii.jpg
1354 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...
There are still a few internal things to do, but the outside is done. It came out pretty close to m...
93-27GGZ.JPG
2465 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...
YEAH! That looks a LOT better!I had a little mishap with an air compressor... It's a long story.
93-28Paint01.JPG
1408 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.
Looking good, but I still want to sandblast & powdercoat the whole front bumper eventually.[url=ht...
93-28Paint07.JPG
2083 hits | 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...
93-28Paint10.JPG
14267 hits | 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 ...
BrushGuard.JPG
1460 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 ...
A screenshot of the CAD drawing for the revised front bumper.IF THE IMAGE IS TOO SMALL, click it....
BumperMkIICAD.jpg
2225 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.

...
A solid bumper starts at the frame. A solid grill guard does, too.[url=https://www.supermotors.net...
Bumper83build.jpg
432 hits | 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...