First I had to rip the old one off.

 

I decided to use the mounts from the old bumper. I cut them off and welded steel bars on. These are going to be my main supports and go all the way through the bumper so I can attach D-rings on them on the other side.

First test fit looks good

I then cut triangles out from either side and bent the bottom up. I then welded them together. Note: the bumper is upside down in the pic.

Drilled some holes and welded in the spindle for the spare tire swing arm.

 

opc1:

 

Right now I'm waiting on more parts to come in so I can put in the trailer hitch and make the spare tire swing arm.

More to come...

 

Subscribed. I like the simplicity of folding in the edges of the tube. I'll probably build mine very similar to how you're doing yours.

 

does the tail gate lower properly or hit the bumper?

 

I checked during the first test fit and it all went fine. I had about an inch gap between the tailgate and the bumper. I haven't checked to see if the tailgate hits the spindle yet. I measured it and it should be good. Just never know for sure.

 

Time to add the trailer hitch! I was a little disappointed when I got the receiver in from Ruff Stuff. I knew that 6" was long enough but I didn't realize that the pre drilled holes for the pin were going to be so far back. Guess I'll have to drill my own.

 

I then cut out the square holes on both sides of the bumper and did a test fit. Looks Good!

 

Time to weld it in place. I'm not a good welder so be easy on my welders...

 

All done and there is just enough room to get the pin in and out. Exactly how I wanted it.

 

Time to figure out how I want to do the swing arm. I need to do some research and think about it. And suggestions let me know!

 

Well, I figured out what I wanted to do with the swing arm. Went out and picked up some metal and tried to finish before dinner. I only measured once instead of twice, and it shows... :banghead
I already fully welded everything. But I have an idea of how to fix it.

 

I cut, bent, and welded the are so now it's level.

Then I attached the spare tire mount

 

Put it back on the Bronco and checked all my measurements. Looks Good!

 

One mistake I made. I forgot that the tail gate isn't straight. It bows out in the middle. I could cut and angle out the swing arm but I'll just leave it. Doesn't bother me that bad.

 

This is how it looks now. List of things that are left:

1. I still need to attach my license plate. I want to try and use the stock lights but I'm not sure how yet.
2. Figure out where and how I'm going to mount my high jack.
3. Get some rubber bump stops.

 

So I realized very quickly that putting the latch for the spare tire carrier on top of the bumper was a bad idea. Can't open the tail gate... So I cut all that off and went with my original plan of just using a wing nut.

 

I also relocated my license plate and used the original lights. What do you think?

 

A little teaser for the next step of relocating the CB antenna

 

love the bumper man! its really similar to what i want to do. i have a few noob-ish questions if you dont mind. i will admit, i dont even have a welder yet and have limited fab skills but i want to learn.

first, how did you cut the holes for the shackles and receiver hitch? plasma cutter? angle grinder? jig saw? i dont have a plasma cutter but it looks like it would be pretty difficult to do without one.

second, what kind of welder were you using to burn in the shackles? thats awful thick metal. i dont think i've ever seen a non-industrial machine rated for 1" metal.

third, did you weld the spindle to the top and bottom of the bumper? if so, how did you weld it to the bottom? the bottom of the bumper is at an angle so it seems like that would be hard to cut/fit/weld.

thanks for taking time to answer the questions, and i cant wait to see the rest of the bumper!

 

I cut all of the square holes with my angel grinder. I first drilled hole in all of the corners and then cut out the edges.

I'm using a Hobart 230v welder with. 035 solid wire and 100% CO2 gas. It's rated up to 5/16 thick Steel. The Steel I'm welding to the 1" thick piece is 3/16 so that should be fine.

Yes I did weld the spindle to the top and bottom. It was difficult to cut the bottom. But what I did was drill both top and bottom holes first. Put the spindle in place where I wanted it. And then traced the bottom of the spindle where I would need to cut it. I then cut it with my angle grinder.

If you have any more questions or even advice feel free to post it. I'm not an experienced metal worker myself. I learned to weld off YouTube. But I like to build stuff so I just go for it.

 

Finished the custom CB antenna mount. Turned out awesome if you ask me!

 

This is how it looks now. Just about done, needs some paint but that's about it.

 

LOOKS AWESOME!! what do you think it can hold tire size wise and would you make some and sell em?

 

I think it will hold as big of a tire as you want really. I have 35s on mine.

I don't think I would make and sell them. Unless the price is right I guess. You can buy one like mine on JBG. This is more of a hobby.

 

That's a clever solution to the license plate, but do the lights illuminate it much on a flat plane like that?

 

honestly I don't know. I know it puts light on the plate, but I haven't tried it at night yet. I'll have to find out.