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My DIY overkill bumper build.

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Old 06-09-2010, 02:33 PM   #1
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Default My DIY overkill bumper build.

Well I started this project by purchasing a 21 ft. section of 2" x 5" x 1/4" tube. I'm not used to working with metal like this and probably could have gotten by with 3/16" wall, but oh well. My original thought was to sandwich the frame mount with the outer bumper sections. Making the frame mount flush with the face of the bumper. Then I would weld my clevis mounts to the frame mounts and notch the tube around the clevis mount. Here's my pile of tube ready for fab.
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Old 06-09-2010, 02:37 PM   #2
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I wanted to trim down the end sections to make them to a 2" x 2" size on the end. I also wanted to go the extra step and keep the nice rounded edges from the mill. So, I pie cut the end sections, then bent the pieces together, and then welded them together.
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Old 06-09-2010, 02:58 PM   #3
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Now it was time to pick out my mount material. My wife's uncle owns the shop that I've been working in and he told me that I could use any metal stock he had laying around. I started looking around for a piece of 1/4" x 5.5" or 6" flat bar to make my frame mounts out of. I was hoping that 5" would work, but it misses catching the highest or lowest bolts, depending on how you mount it. I couldn't find any 1/4", but did find a section of 3/8" x 6". I know this is kinda overkill, but hey, it's free. So, I had to go and rethink my design. What I came up with was to make the mount one piece from the big oval, sleeved hole all the way out to the tip of the clevis mount. I still sandwiched the mount between the tube but the clevis mount stuck out from in between the tube. I also added one piece of the 3/8" flat to each side of the clevis mount to make it stronger for pulling. The additional pieces were also trimmed smaller than the mount sticking out so there was area to weld it in real good.
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My DIY overkill bumper build.-1_0-2-.jpg   My DIY overkill bumper build.-clevis-mount.jpg   My DIY overkill bumper build.-clevis-mount2.jpg  
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Old 06-09-2010, 03:03 PM   #4
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Here are some shots after the main body was welded, but the additional 3/8" flat has not been added.
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Old 06-09-2010, 03:05 PM   #5
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Here's a couple shots while I'm trying to test it out without mounting it.
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Old 06-09-2010, 03:08 PM   #6
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Next was to add the 2" x 2" tube that protects the fenders.
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Old 06-09-2010, 03:10 PM   #7
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Here's some close ups of the fender protection.
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Old 06-09-2010, 03:15 PM   #8
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Now it was time to sand it down, primer, and paint it with aerosol bedliner. Then I got to install it. Found out 2 things. #1 it's an extremely tight fit. # 2 is that 2 of the bolt holes on each side didn't line up to the existing holes in the frame. A little quality time with the air die grinder fixed that on the driver's side. Now I just need to do it to the pass. side.
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Old 06-09-2010, 03:17 PM   #9
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This makes phase 1 of the build complete. Phase 2 will come when I buy my winch and buy some tube for the front.
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Old 06-09-2010, 03:21 PM   #10
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This looks good, I like it, How much that thing wiegh
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Old 06-09-2010, 03:24 PM   #11
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Thank you. It weighs just a little over 80 lbs. Like the title says, overkill.
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Old 06-09-2010, 03:36 PM   #12
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Bumper looks good... feel sorry for anyone or anything that ever gets hit by that thing... are you going to build a rear bumper along the same lines??
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Old 06-09-2010, 03:40 PM   #13
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nice
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Old 06-09-2010, 03:49 PM   #14
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That looks great! Good job with tons of overkill
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Old 06-09-2010, 04:07 PM   #15
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Frigging Sick!!!!! Love every bit of it. Great fab!!
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