just finished new rear bumper

[ForOffRoadDriving]

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]

turned out pretty good, i like it

 

[bduke23]

That bumper is awesome, great work!!

Also great write up.

 

[alwaysFlOoReD]

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?


Richard

 

[93_RangerSC]

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]

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]

Bumper looks good! Where did you get those lights you put in there?

 

[disciplerocks]

Very nice work.

 

[IndianScout]

very nice work

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

love the tire carrier..

 

[93_RangerSC]

thanks man that oughta give me a rough enough idea on my brackets

 

[ForOffRoadDriving]

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]

Nice fabbin dude. SAS 4X4 conversion time.

 

[schaffer]

looks pretty good...question tho.

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

 

[LIMA BEAN]

A to Z makes a great pivot kit.

http://www.atozfabrication.com/store/Tire-Carrier-Swingout-Heavy-Duty-Hinge-Kit.html?page=1

Heres another but more coin.

http://www.4x4labs.com/products/rear-bumpers/heavy-duty-spindles/

Nother

http://troutindustries.easycgi.com/TIndustries/pc/home.asp

 

[ForOffRoadDriving]

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.

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