Alrighty so I managed to sell off my 'ol Handler 135, and I made a little upgrade...
Miller 211 MVP! This thing kicks butt!
To take full advantage of this guy, I had to redo the wiring in my garage. I wired in a new subpanel so now I have 220v service & room for expansion circuits. I have a powdercoat oven & air compressor in mind down the road...
I learned a lot about wiring in a very short period
SO. Back to the bumper.
First thing I had to do was make cut-outs for my clevis mounts. Some very patient and careful angle grinder work turned out nicely.
I cut out the slots with the entire bumper tacked together still, but you'll notice there are some fairly long weldments on a few pieces. This is because I had to take the bumper back apart in 2 halves to weld the inside portion of the clevis tabs that were sticking through to the inside.
These were the first real thick pieces I welded before, and I seemed to get decent heat and penetration. I had to go slow though and allow time to cool so I didn't get warpage in the 3/16" plate.
A note about the tire carrier spindle. My original plan was to weld in the spindle at this time with the bumper in 2 halves so I could weld 360 degrees around the bottom inside the bumper.
However, I decided not to do this, because I called A to Z fab specifically to ask what their recommended procedure for welding the spindle was. I wanted to take all precautions for avoiding stress cracks & failure in the future due to excessive heat/too rapid cooling.
Their recommendation was to simply weld in the spindle 360 degrees around the top, and 360 degrees around the bottom with all pieces at room temperature (~65 deg they said). Most importantly they said not to weld in the spindle until all the structural welding of the bumper was complete so that the squareness/orientation of the spindle would not be thrown off by potential warpage.
Therefore, I decided that I would weld it in 360 around the top, and only 180 degrees around the bottom from what I could reach with the bumper assembled. Then, I plan to add an additional gusset about midway on the spindle on the inside of the bumper for additional strength. We'll see how that goes.
1979 Bronco 400m 0.060 over 'Black Betty'
-Edelbrock Carb & Manifold, Hedman Headers, Flowmaster Dual Mufflers, Comp Cams Extreme Energy Cam & Valvetrain Kit
-Duff LAs, WH progressive coils, Bilstein 7100s Lincoln HB, York OBA, Taurus Radiator Fan