1st bumper attempt in progress

[timpat92855]

I posted this on ranger-forums but thought I would share it with you. Please keep in mind I am a machinist and not a fabricator. I am still in the blueprint, template stage right now but things will be going quicker once the metal gets here that I ordered.

Materials:
16ft of 2x5x.125 rectangle tubing
3ft of 2x2x.125 square tubing
2ft of 2.5x2.5x.188 for mounts (not ordered yet)

The truck as she sits now

The cardboard bumper. It needs some minor tweaks, cds are for fog lights

I tried coming up with a mount design without having the bumper done and that is kicking my butt. I know it will be easier once I have the bumper but I like having a plan. This is what I came up with as a template for the mounting system using the factory tow hook holes as the attachment points. I figure if I can get pulled out by the crossmember the bumper can bolt to it. Still need to do some figuring but it is close to what it will be.

and the progess made today.

All comments and suggestions are welcome I am listening to anyone who has advise. Like I said I am a machinist and not a fabricator. Scary thought.

 

[02RangerXLT]

Just make sure that if you don't have experience welding, to have someone who knows how to weld it do it for you.

You look like you're planning everything out, that is good.

I'll keep following the build!

 

[85_Ranger4x4]

I would weld all around in addition to the bolts holding the two halves together. I don't know how happy those bolts will be in an accident being loaded in shear like that. It would be a bummer to go through all this work and have the bumper fall off in an accident.

And your bottom holes look smaller than the top ones.

 

[timpat92855]

I noticed my holes being different sizes but with it being on paint I said it would work haha.

I work at a place that makes hydrulic cylinders for catepillar. I will have the welders weld it up for me. I mean if they are cat certified they should be able to weld a bumper together. I hope atleast...

Weld around the 2 halves? I did not think about that as I want something to give in case I have a wreck. I would rather the bumper act like a shock absober than a wall. Am I going about it the wrong way? A 5/8-11 grade 8 bolt has a shear of over 20,000 ksi. I just don't want a bent frame.

 

[Dugan]

The way I start every bumper I do is by cutting off the frame knuckles and inserting a peice of C channel. Then I mount a plate to this usually for a winch and build from there. Its the easiest method of getting a base.

 

[85_Ranger4x4]

I noticed my holes being different sizes but with it being on paint I said it would work haha.

I work at a place that makes hydrulic cylinders for catepillar. I will have the welders weld it up for me. I mean if they are cat certified they should be able to weld a bumper together. I hope atleast...

Weld around the 2 halves? I did not think about that as I want something to give in case I have a wreck. I would rather the bumper act like a shock absober than a wall. Am I going about it the wrong way? A 5/8-11 grade 8 bolt has a shear of over 20,000 ksi. I just don't want a bent frame.

I was just giving you a hard time on the holes.

I just really don't like the looks of the way the bolts are In addition to the sheer the top bracket is going to be trying to twist off the bottom bracket. After finding your BOM though... 3/16" won't break a 5/8" bolt anyway so it is a moot point.

If you want it to give you are going to need to do a lot of math to figure up how much is enough and how much is too much. It is something OEM's still struggle with.

 

[timpat92855]

My mounts are now in question. I'm going to let eng. at work look them over and see what they suggest. Thanks for bring that to my attention.

I want to leave my factory crossmember on the truck due to maybe wanting to return it to stock one day. Thats why the mounting brackets are key to the build. It makes it ALOT harder, I know but I dont wanna cut anything off the truck thats factory.