Kenneth's Front Bumper Build
 

Going to get the materials tomorrow. I'm using 1/8" plate for the bumper and 1/4" for the frame mounts. I plan on welding another piece of 1/4" to the D-ring bracket to make it a 1/2" thick.

This will be the time I've ever fabricated anything substantial. I just bought a welder a few weeks ago so this will be a learning experience. I'm open to all criticism and praise. If anyone wants the solidworks files let me know and I'll upload or email them.

I'm interested in seeing the progress on this build

I'll be posting pictures as I go. Might take me a few weeks though. I ended up getting 1/4"x4 flat bar for the piece that attaches to the frame. It was a ***** to cut haha. I caught my miter saw on fire!

Any updates!?

Well I burnt up 2 HF cutting discs and one dewalt jigsaw blade and this is all I got cut. I wish I had a plasma cuter, I think I'll go by Lowe's and get a nice cutting wheel for my angle grinder.

http://img.tapatalk.com/d/14/07/04/gudy6e5e.jpg

Plan on going through A LOT of cutting discs. I usually pick up a pack of at least 10 and go through most of them, especially when cutting plate steel like that. Good luck on the build though. Looks like you have a good plan!

I'm almost exactly copying your design haha. I got the rest cut with only 1.5 dewalt cutting discs.

http://img.tapatalk.com/d/14/07/05/a7emeju5.jpg

70% bent. I am cutting completely through about half of each fold line and scoring about halfway through the rest. This makes it pretty easy to bend with a rubber mallet.

http://img.tapatalk.com/d/14/07/05/8ytutuvu.jpg

http://img.tapatalk.com/d/14/07/05/urasuga4.jpg

Just finished welding the bumper part.

http://img.tapatalk.com/d/14/07/13/5uda5apu.jpg

http://img.tapatalk.com/d/14/07/13/ravynypu.jpg

http://img.tapatalk.com/d/14/07/13/pygesy9y.jpg

My welds look pretty bad after grinding them. I am using 1/8" 6011 on 1/8" sheet at 95 amps and it was burning through some places so I tried to go faster than I thought I should. This is my first welding project so I am open to any constructive criticism.

About to go pull my old bumper and figure out how to attach this thing.

Honestly, not bad for your 1st welding project. I've seen much worse. Keep at it, go slower, and remember: practice makes perfect! Keep up the good work.

Arc welding can be really tough on finish welds like that on the outside. If you have access to a mig welder, it's much easier. But if not, make sure the electrode is closer to the metal when you're welding, and most importantly make sure that this distance and the speed that you travel is consistent. Most defects and trouble spots on a weld are caused by inconsistency.

If you want to try to fix those low spots in the weld, you can always just go over it again and then grind it down and repeat if necessary. That's what I normally do. It's really looking good though!

Yeah I could tell when I had a good run going. I wish I had a mig welder but I'd rather get a nicer mig later and learn on a cheap machine. I'll have to get some 3/32" so I can go slower. What size rod would you use on 16 ga steel? My next project is going to be a toolbox for the back.

6013 or 7018 in a 3/32 size will leave much nicer welds. I'd go with 7018 personally.

You can also get 1/16 rod for that thiner sheet metal.

i usually weld 6010/6011 1/8 at 75-85 amps. 3/32 7018 at 85-90 amps. for a project like this i would've used 3/32 7018. nice though for a first project. welding takes a lot of practice.

Not sure why you have it in your kitchen but it looks good so far.