Offroad Trailblazers and Envoys

Another Rear Bumper Fab Thread

Any special projects involving a decent amount of fab work (bumpers, sliders, roof racks, etc)

by mason10198 » Sat Feb 03, 2018 4:00 am

Got the main step plate in! Unfortunately had to cut it as two halves because my CNC isn't big enough to cut the whole thing. Put 2 massive gussets under each "half" (post a pic of those later). Should be getting more done this weekend... It almost looks like a bumper now!ImageImage
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by bartonmd » Wed Feb 07, 2018 4:47 pm

Looks like a good start!

Mike
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by mason10198 » Thu Feb 08, 2018 7:29 pm

Decisions on hinge design... This is what I have to work with: https://goo.gl/cfDf9p
I had originally planned on cutting off the bottom "tab" of the bracket and welding it into the bumper where it is sitting here-
IMG_20180203_114743943.jpg
realbracket

-and then drilling a hole in the bumper (what i'm calling the "step plate") for the hinge bolt to go through where the bottom tab of the bracket would have been, and then welding the nut inside the bumper, on the underside of the step plate.
On paper, that would look like this from the top-
IMG_20180208_150306967.jpg
idea1sketch

-and when chucked into the Fusion model, looks like this-
Screen Shot 2018-02-08 at 3.38.12 PM.png
idea1model

BUT with a little more thinking, I think it might be better to essentially forget that bracket, and just fully incorporate one into the bumper itself. Which would be almost exactly the same as what I just showed above, except 'pushed' towards the passenger side, into the 'box' that the step plate wall and passenger wing come together to make. Which, on paper, looks like this-
IMG_20180208_151224687.jpg
idea2sketch

-and wait, what do you know... I'm so ignorant i didn't realize thats exactly what Mike did right here, just with heims instead of a bought hinge-
IMAG1145-1.jpg
mikeissmarterthanme

SO, when I modify that idea a little bit to work with my big phat hinge instead of heim links, I get this-
hinge.png
betteridea

-which I think will be a way better option both functionally and aesthetically.
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by HARDTRAILZ » Fri Feb 09, 2018 9:35 am

I searched a good while on the rear bumper and gave Mike a ton of ideas. I really liked the heim for adjustability if needed at all and it did prove to work well.

I need to get the swings back on my truck, but been wanting to redo the jerry can mount side with a platform that could hold either a couple jerry cans of a cooler or similar. Something a bit more useful since I really dont need to haul fuel around constantly
I hate to advocate weird chemicals, alcohol, violence or insanity to anyone...but
they've always worked for me.
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by mason10198 » Fri Feb 09, 2018 11:30 am

I wanna go the RotoPax route as far as fuel storage. Everyone knows it's dumb expensive, but it is super convenient to be able to switch sizes and have water cans/dry storage that work with the mounts.
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by mason10198 » Fri Feb 09, 2018 3:20 pm

After a little more work in Fusion:
GIFs are so much fun...
Image
Image
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by Trail X » Fri Feb 09, 2018 6:15 pm

Looks good, just don't forget to draw in your welds. I think you're going to run into your welds on full open. It'd make sense to also have some space between the between the arm and the step plate. Normally you want it to at least ride on a washer or two so you're not scraping your arm across the step plate.
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by mason10198 » Sat Feb 10, 2018 12:56 pm

Yes, I still have to raise everything up a fraction or two to get it to fit, I just hadn't done that in the model yet. Working on that part and the radius today hopefully
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by mason10198 » Wed Feb 14, 2018 5:51 pm

Mostly finished with the hinge side. Nasty welds until the gap fill on the sides of the radius. Underside hasn't been welded yet either, gotta go refill my bottles. Those random looking plates on the bottom of the mounting arms are just spacers to help line up the 90 degree on the angle fit up in the rounded corners of the frame rail, so didnt spend much time measuring or cutting those. Just kinda threw them in there and welded them on.
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