Gordinho's Rear Bumper Project

[MrSmithsTB]

Nice progress! Should definitely look nice once completed. Wonder how difficult it would be to adapt to a 2" body lifted TB.

[Gordinho80]

Thanks. The mounting legs are pretty much as far down on the channel as they can be. For a 2" BL, I'd suggest either a taller C-channel or weld flat stock on the top at an angle to fill the gap. I'm filling the top with flat stock, but finishing it flat.

[MrSmithsTB]

Thanks. The mounting legs are pretty much as far down on the channel as they can be. For a 2" BL, I'd suggest either a taller C-channel or weld flat stock on the top at an angle to fill the gap. I'm filling the top with flat stock, but finishing it flat.

Same size channel with vertical filler is what I am thinking. Maybe even the same bumper with some custom cut gap guard like what is used for Jeeps. Taller channel might look a little out of place.

[Trail X]

I like it Mario! Curious what you're plans are for the Ls that are protruding.

Can't wait to see it with the 'wings'.

[steveroche]

That's looking real good as a base so far. I am curious, did you say the piece on there right now is 5 foot in length? I am going to use that same length but instead of filling in with more C-channel i will use tubing to wrap the whole bumper. I just need to find somewhere to get C-channel from... :/

[Gordinho80]

I agree... Taller channel wouldn't look right.

James, I'm using those LS as shackle mounts. Going to add a piece of flat stock to widen it, then drilling the hole for the shackle. I'm going to grind then down so they don't protrude from the bumper that much... Just enough for the shackle.

I started with a 10' section, mounted it on center.... Look at first few pics on page 1.... My neighbor works in commercial building construction. That 10' piece cost me $0. Nice!!!

[steveroche]

I started with a 10' section, mounted it on center.... Look at first few pics on page 1.... My neighbor works in commercial building construction. That 10' piece cost me $0. Nice!!!

Well that is lucky haha, always good to have friends like that. Also i meant how long is that piece now that you have it cut down?

[Black EXT]

i was wondering your C section it's the same that i used in my front Bumper?
0.25 inch thick? (6.4mm) with that kind of bumper you can start hitting trains jajajaja

[Gordinho80]

The base piece of C that remains after cutting the sides is 4'.

I do believe my C is the same thickness. It's beastly. The 10' section weighed in at over 80lbs(36kg).

[Black EXT]

The base piece of C that remains after cutting the sides is 4'.

I do believe my C is the same thickness. It's beastly. The 10' section weighed in at over 80lbs(36kg).

Beastly! with that you may throw away that tire carrier and weld a new one ...

I suggest you use iron of no more than 2.5 or 3mm thick for the sides of the bumper i don't think you need more than that...
you can start cutting the first "wing" like i did and welded with the angle you want... and then measure the following parts with cardboard, soldering and copy each and every one of the feet, to make the other corner.
so I did and it was easy, they are just ideas!

Juan Pablo

[Gordinho80]

So I got myself a HF welder... thanks to Mooseknuckle for actually picking it up for me!

Spent some time yesterday working on the bumper.





Then again some time today...





It's coming along! Its starting to not look like a piece of C-Channel anymore.

[NC_IslandRunner]

Starting to look good!

[Trail X]

Looking sweet dude! That's quite a taper on the ends, I like it!

Need a picture of it on the truck now!

[Gordinho80]

Thanks. The taper is a 4" rise. I decided on going with that much taper cause it allows the side pieces of channel to sit very close to the quarter panel. I just need to figure out a way to secure the sides to the vehicle. They will actually slide over the existing hangers that are used to hold up the factory bumper, but I'm looking for something more sturdy. I didn't want to put the bumper back on without addressing this, as I'd probably end up leaving it on for a little and didn't want to put that stress on the sides/hangers.

[MrSmithsTB]

Lookin good, brother! Picked up a welder, huh? Do I foresee someone being able to help fab up some brackets for tube bumpers?

[Gordinho80]

Yeah man... this little guy ain't the best... but it will get stuff done with enough passes. I may go back and get a slightly larger unit instead... not sure yet.

[MrSmithsTB]

Did you get the 120v of 220v model?

[Gordinho80]

I got the smallest one... 90 Amp Flux Wire... http://www.harborfreight.com/90-amp-flu ... 98871.html

[bartonmd]

Yeah man... this little guy ain't the best... but it will get stuff done with enough passes. I may go back and get a slightly larger unit instead... not sure yet.

If you just want cheap + flux core only, a Hobart 125 can be had for $350 shipped:
http://www.northerntool.com/shop/tools/ ... _200447703

Or if you want 120V still, but want a little more amperage, the Hobart 140 with gauges (just add your tank for $150, or run flux core like it is) can be had for $500 shipped:
http://www.northerntool.com/shop/tools/ ... _200306073

If you want to do real stuff, and want a 220V welder, the Lincoln 180 is $730 shipped:
http://www.northerntool.com/shop/tools/ ... _200405531

and the Hobart 190 is $750 shipped:
http://www.northerntool.com/shop/tools/ ... _200482378

[MrSmithsTB]

Concerning that little guy you picked up, are you happy with the weld strength? I have been debating getting that one for months, due to the fact that I rent and only have 15a outlets in the garage. Can't run a 220 line or I would. I'm sitting on a coupon that gets me one of those for $90 and would probably get one this week if I know the wells are going to be sound. Looks like a nice starter until I move in to a permanent shop.