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Front Bumper Project

From 1991 Ford Bronco “Cookie Monster”, documented by Meixter.

29 photos
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1991 Ford Bronco - This is what it looked like when I bought the Bronco 1991 Ford Bronco - Here it is ready for our first Broncofest in 2003 1991 Ford Bronco - This is what it looked like when I began this project 1991 Ford Bronco - 1/4" x 8" plate steel for the new bumper 1991 Ford Bronco - See ya later 1991 Ford Bronco - Here is the Bronco with no bumper and the plastic air dam removed from under the grill 1991 Ford Bronco - I used a cutting wheel to score the back of the plate steel where I wanted to bend it 1991 Ford Bronco - I then bent it to match the shape I had drawn on my workbench 1991 Ford Bronco - After bending I welded the bends front and back 1991 Ford Bronco - Close-up view of a metal part showing a welded seam. 1991 Ford Bronco - All welded up and ready for paint 1991 Ford Bronco - Painted 1991 Ford Bronco - Test fit 1991 Ford Bronco - It fit just as planned (better to be lucky than good!) 1991 Ford Bronco - I drilled it for 3 grade 8 bolts on each frame horn, these are temporary for now 1991 Ford Bronco - Here are the upper tubes tack welded on 1991 Ford Bronco - Low-angle garage shot of a blue lifted truck's underside showing the steering gearbox, frame and a large front tire. 1991 Ford Bronco - Front view of a 1991 Ford Bronco showing the grille and custom bumper. 1991 Ford Bronco - All tubes tack welded in place 1991 Ford Bronco - I then took the bumper off to complete the welding on the tubing 1991 Ford Bronco - A custom front bumper project, made of metal and tubing, lies on a concrete floor. 1991 Ford Bronco - I welded and grinded alot from this point to get it to look decent 1991 Ford Bronco - This is how it ended up with a coat of paint 1991 Ford Bronco - Hole for the WARN 8274 1991 Ford Bronco - Finish paint 1991 Ford Bronco - Front view of a 1991 Ford Bronco a custom bumper with an integrated winch. 1991 Ford Bronco - On the truck and lookin sexy! 1991 Ford Bronco - On the advice of a couple of friends, I added a bottom for strength 1991 Ford Bronco - Another view of the bottom