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Rear Bumper Project

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

34 photos
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1991 Ford Bronco - The raw material, I had a pro weld the 3/8" tabs on this 6" c channel at work for me 1991 Ford Bronco - Bye-bye 1991 Ford Bronco - License plate off, wiring disconnected 1991 Ford Bronco - Off 1991 Ford Bronco - What a wiring mess! 1991 Ford Bronco - Trailer wiring harness and hitch removed 1991 Ford Bronco - I removed the Pollack plug and rewired the harness with just a 4 pin connector for my utility trailer 1991 Ford Bronco - Paying omage to the steel gods as I prepare to cut 1991 Ford Bronco - Steel cut to length and the tabs that will bolt to the frame have been cut 1991 Ford Bronco - Test fit 1991 Ford Bronco - Holes drilled for bolting to the frame, I am reusing the holes that are in the frame 1991 Ford Bronco - I beveled the bottom for max clearance. It took a few cutting wheels and 2 sawzall blades to cut the 3/8" steel 1991 Ford Bronco - Holes for the hitch and license plate lights 1991 Ford Bronco - I am taking no chances, I beveled the crap out of the hole where the hitch will be 1991 Ford Bronco - I also beveled the receiver material 1991 Ford Bronco - I welded the backside of the receiver first 1991 Ford Bronco - Front side after welding the back 1991 Ford Bronco - I preheated the frontside 1991 Ford Bronco - First weld deep in the groove 1991 Ford Bronco - Next weld, inside and outside of groove 1991 Ford Bronco - Then I filled it up 1991 Ford Bronco - Ground down and ready for paint 1991 Ford Bronco - I then added bracing to the backside of the receiver 1991 Ford Bronco - Welded up 1991 Ford Bronco - Here you can see the holes drilled for the license plate 1991 Ford Bronco - Checking the fit with the hitch I use as a recovery point 1991 Ford Bronco - I am reusing the factory license plate lights in the new bumper 1991 Ford Bronco - Black metal bumper part with two circular silver reflectors and a square cutout is on the floor. 1991 Ford Bronco - Finish paint 1991 Ford Bronco - Mounted 1991 Ford Bronco - License plate installed 1991 Ford Bronco - Lookin good 1991 Ford Bronco - Massive improvement on exit angle! 1991 Ford Bronco - Lookin sexy!