• Welcome Visitor! Please take a few seconds and Register for our forum. Even if you don't want to post, you can still 'Like' and react to posts.

just finished new rear bumper


ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
i just copied this from my build thread, but here ya go
its been a while since ive posted any updates on Thumper, but this post shouldnt disappoint! i had a four day weekend starting on friday so i spent 10-12 hours each day working in the garage to create a rear bumper for Thumper. i also wandered into the autometer book at work and got myself a vaccum gauge and a molded A-pillar mount for the gauge. it probably wasnt necessary as its just one more thing to distract me from the road, but its cool none the less. enough blabbing, on to the pics!






i started collecting steel and supplies months ago, but i was finally able to get the important pieces- the channel and the diamond plate. ive got about $100 into materials at this point.



next i lay out the general shape/ contour of the bumper using paint mixing sticks that i have riveted together end to end. they pivot to my desired angle when i hold them up to the truck and then i can put my protractor on them and find the angle that i need to make my cuts at.




now that i have my angles layed out on the smooth side of the diamond plate i can transfer them to the channel and mark where i will make my relief cuts. once the cuts are made the channel is heated and bent until the angle matches the paint sticks. this ensures that both sides match and everything will line up in the end.






now that its bent its time to see how closely it matches the diamond late layout that i made. it needed a few adjustments and then it was good for a test fit.





im happy with the shape and overall look so its time to cut the diamond plate and test fit it.




for the frame brackets im using 3"x3"x3/8" angle iron. i marked my holes and drilled them on the drill press. 4 1/2" grade 8 bolts hold each side in place.







the channel has been tack welded to the angle supports so now its time to test fit the diamond plate again. i need more metal in the back since i didnt notch the angle to fit flush with the top of the channel so i added another angle iron support which will level the plate and give it more bracing (and weight).





time for welding!







this is a pic from intermission day. i took a break from the truck and worked on terras sport trac and on my friends 99 ranger.



heres a teaser pic of whats to come



back to work, my final day off and i have to get this tire swing made! i started around 10am and finished at 3am, what a day!















time for bed....

heres how it looked when i woke up and took a pic before work

 


86 slo-vo

02/2011 OTOTM Winner
OTOTM Winner
TRS Banner 2010-2011
Joined
Jan 5, 2009
Messages
4,510
Reaction score
36
Points
0
Location
owensboro, KY
Vehicle Year
1994
Make / Model
ford
Engine Size
4.0
Transmission
Manual
turned out pretty good, i like it
 

bduke23

New Member
Joined
Feb 23, 2010
Messages
369
Reaction score
1
Points
0
Location
Saskatoon, Sk
Vehicle Year
1993
Make / Model
Ford
Engine Size
3.0
Transmission
Manual
That bumper is awesome, great work!!

Also great write up.
 

alwaysFlOoReD

Forum Staff Member
TRS Forum Moderator
TRS Banner 2012-2015
TRS 20th Anniversary
Joined
Apr 13, 2009
Messages
13,868
Reaction score
5,029
Points
113
Location
Calgary, Canada
Vehicle Year
'91, '80, '06
Make / Model
Ford, GMC,Dodge
Engine Size
4.0,4.0,5.7
Transmission
Manual
2WD / 4WD
4WD
Looks good.
How do you think the tire holder pivot will hold up? It looks like it might sag with the poly bushing.
And where did you get the labels for your tool box drawers, did you make those too?
:icon_thumby:

Richard
 

93_RangerSC

New Member
Joined
Jan 12, 2008
Messages
339
Reaction score
0
Points
0
Age
34
Location
Charleston, SC
Vehicle Year
1993
Make / Model
Ford
Engine Size
4.0
Transmission
Manual
pretty cool i like it!
can you PM me the dimensions of that angle you got bolted to the frame?like where you cut and put the holes
 

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
thanks guys im glad you all like it. as of now i feel that the pivot point is the weakest link in the set up, but i made it with what i had on hand so unfortunately it wasnt made with the most choice materials. im still searching for a better design, and then weighing the costs. as for the dimensions on the angle, it was 3"x3"x3/8" x 20" long and i cut the notch to clear the rear spring hanger 5" in from the front end. as for the holes in the angle i measured 9" from the nothced side and marked a line across the bottom so i could line it up with the end of the frame rail, then i clamped it to the frame and marked the spot where the head of the bolt that holds the rear crossmember in place protrudes. i drilled those holes with a 3/4" bit and then clamped the angle back in place and marked the remaining holes with a layout pencil. i used a 5/8" drill on the rest of the holes so my 1/2" bolts would have some "wiggle room". i usually only make up rough sketches to work from and figure out final dimensions as i go, so i dont have any blueprints to share per say.
 

whocares

New Member
Joined
Dec 25, 2009
Messages
304
Reaction score
2
Points
0
Transmission
Automatic
Bumper looks good! Where did you get those lights you put in there?
 

disciplerocks

July 2011 OTOTM Winner
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
TRS Banner 2012-2015
Joined
May 27, 2010
Messages
4,522
Reaction score
53
Points
48
Location
Evansville, IN
Vehicle Year
1989
Make / Model
Ford
Engine Size
4.0
Transmission
Automatic
Very nice work.
 

IndianScout

New Member
Joined
Sep 23, 2010
Messages
103
Reaction score
0
Points
0
Location
ND
Vehicle Year
1993
Make / Model
Ford
Engine Size
3.0 Vulcan
Transmission
Manual
very nice work

I really need to get someone to make me a rear bumper or buy one...

love the tire carrier..
 

93_RangerSC

New Member
Joined
Jan 12, 2008
Messages
339
Reaction score
0
Points
0
Age
34
Location
Charleston, SC
Vehicle Year
1993
Make / Model
Ford
Engine Size
4.0
Transmission
Manual
thanks man that oughta give me a rough enough idea on my brackets
 

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
i just revised the carrier pivot design to something more permanent, more pics will come when the parts arrive and i weld them up.
 

MAranger

New Member
Joined
Feb 4, 2008
Messages
350
Reaction score
0
Points
0
Location
Ipswich, MA
Vehicle Year
1994
Make / Model
Ford
Engine Size
245c.i.
Transmission
Manual
Nice fabbin dude. SAS 4X4 conversion time.
 

schaffer

New Member
Joined
Oct 4, 2010
Messages
175
Reaction score
0
Points
0
Location
PA
Vehicle Year
1998
Make / Model
Ford
Engine Size
4.0
Transmission
Manual
looks pretty good...question tho.

the picture with the sport trac....did you build the bumper on that ranger too?
 

LIMA BEAN

Well-Known Member
TRS Banner 2012-2015
TRS 20th Anniversary
Joined
Aug 26, 2007
Messages
3,710
Reaction score
140
Points
63
Location
ALASKA
Vehicle Year
1988
Make / Model
Ford
Transmission
Manual
2WD / 4WD
4WD

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
looks pretty good...question tho.

the picture with the sport trac....did you build the bumper on that ranger too?
thats actually just the front of the truck that the rear bumper was being built for, but yes, i made that one too. i used the same size channel and diamond plate for the front and used a bolt on brush guard from a full size chevy that i reworked to tightly fit the channel. then i used a tube kinker to bend the tubes to protect the headlights (its all in the build thread if you have lots of free time). it took me a couple of weeks to build from scratch, mostly because i spent alot of time mocking up and brainstorming an original design, but the rear only took me 2-3 days because i already had a basic design to follow so all i had to do was mock it up and then make sure the gaps were all acceptable before welding. i recieved the trailer spindle and bearing kit ill be using for the new pivot from the UPS man yesterday, so all i need to do now is get ahold of the right size tube to house the spindle and bearings and re-fit the swing out and start welding.:icon_welder:

:EDIT: i just ordered a machined pivot tube from trout industries - thanks lima bean!
 
Last edited:

Sponsored Ad


Sponsored Ad

Staff online

Member & Vendor Upgrades

For a small yearly donation, you can support this forum and receive a 'Supporting Member' banner, or become a 'Supporting Vendor' and promote your products here. Click the banner to find out how.

Truck of The Month


Kirby N.
March Truck of The Month

Recently Featured

Want to see your truck here? Share your photos and details in the forum.

Follow TRS On Instagram

TRS Events

25th Anniversary Sponsors

Check Out The TRS Store


Sponsored Ad


Sponsored Ad

Sponsored Ad


Amazon Deals

Top