definately looks tough i cant wait to see finished product!! any ideas for fog lights? id like to see them in the bumper i think that be sweet.

 

Looks badass!

 

This is looking really nice now that you're nearing the end.

 

I will be off Thur/Fri/Sat. Hope to get the bottom skirt cut and tack welded for a more finished look. The I can pull the whole thing off and weld it all up.

This is a lot of work. Now I understand why shops charge so much for these bumpers!

 

Can't wait to see the finished product. Your doing an awesome job sofar!

 

Thanks. I have been lazy over the holiday and not even worked on it. Got to looking at it yesterday and am debating whether or not to fool with putting the skirt on around the bottom. I may just finish the tow hooks and cap the ends of the bumper at the flares and call it good.

I can always come back and put the skirt on if I want later. I would have to repaint the whole thing though. Decisions decisions....

 

I personally like the looks of the skirt around the bottom but its not a must. The bumper still looks good without it. And ya you can always come back later and strip the paint and finish it.

 

how did you go about matching the top of it to the header panel?

 

scribed

 

Are you talking about the top of the bumper that matches the contour of the grill and headlights?

I think that is what you are talking about. I made marks on it where I wanted the bumper to angle back and notched it out. Then on the front I scored a line with my grinder cutting blade about halfway through the metal. Once I had the notches cut and the front scored I was able to bend the ends to the angle needed to match the contour of the grill/headlight assembly.

After I got it fitted right, I pulled it off and welded the top and front then cleaned it up with the grinder. I should have taken pictures of that part of the process. I was just too excited to get it done and see what is was going to look like.

 

what was the initial length you cut it to before you bent the pieces in? I am going to pick up a piece of angle on my way home to do this same bumper.

 

on the front? Hrrrm I could be completely wrong but let me draw something. If im thinking correctly you just reduced the strength of those bends a little. here's my awesome paint representation. taking away material and then re welding it is definitely the way to go i just think you did it on the wrong side, the fact that it is angle iron and that you welded the top is great, that will do wonders. what i would do is bend up a plate to match the contour and weld that in with rosette welds and stitching, or add a fat gusset. just my .o2 because i love the look and affordability of it over making one massive thing out of box or plating up down left right etc, and id hate for you to damage it down the trail because of when someone like me with very little bit of fab experience (or more) coulda said ey, check that out. Cant wait to see it painted!

so number 1 is what i think you said and number 2 is what would probably be better. see how when it bends it stretches the thinner part of the metal is all there is? i know you said you welded over it, i just think having the metal butt up against itself is better. if you do a contoured reinforcement just bend it regularly (vise and a bfh!) drill the holes first if you are going to rosette weld it.

damn I need a welder haha then i can put my welds where my mouth is and more metal where my rig is...

 

looks good i made mine out of 2x6 inch tube cut the back heated with a torch and got my angles ..mine is 1/4 inch thick and it about 60lbs..my d rings are 1 inch thick,had them laser cut at work..yours may be a little thin..my brackets are also 1/2 thick..mine looks similar but mine is a zj and had more angles..i will put pics up soon..

 

would i be able to get dimensions on the mounting tabs? and you said 1/4 in 3x5 angle right? looks good. lookin at makin one like this. love the look of a low profile bumper

 

Good looking bumper, nice work. Jerry has a point but you can add strength by welding in a gusset on the back side at the bends and should be strong enough.