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Old 11-19-2007, 01:04 AM   #1
The Bucking Bronco
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Easy to build tube bumper & CHEAP

I wanted to see if I could make a functional tube bumper cheap and with tools that a lot of us have or have access to:

Tubing I had left over from roll cage 1 3/4 X .120 DOM

welder

Harbor freight bender (the 1 1/4 pipe die worked great )

harbor freight tube notcher (I only notched a couple of pieces so a grinder would have worked just fine)

4in grinder

I started by bending the main bar 18in from the ends


I wanted to keep it simple so I re-used the original mounting brackets
I cut and notched two 3in pieces of tube and welded them to to brackets and then attached the main tube


next I cut two 8in tubes to connect the bottom and cut two tubes to complete the outer ends


then I took a winch mounting plate and another piece of tube for the center and welded it all together.
Its not bolted on tight so its sitting about a inch low


here is what it looks like off and painted


A few extra things to add. I capped the frame for looks and I probalby will plate the crumple zones for strength.
I kept the original mounting brackets to keep it simple but when I plate the crumple zones I plan to gusset the back of the piece that is welded to the frame.
The harbor freight bender work great for just these light bends, if you had to do anything more then a few degrees I would have used a different bender.

I hope to get this completed tomorrow so I will hopefully have more pictures to come.
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Old 11-19-2007, 01:10 AM   #2
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some side pics would be nice
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Old 11-19-2007, 01:14 AM   #3
The Bucking Bronco
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I will get some up tomorrow
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Old 11-19-2007, 11:05 AM   #4
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kewl
you gonna put a winch on it?
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Old 11-19-2007, 11:12 AM   #5
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Old 11-19-2007, 11:59 AM   #6
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Can you show what the HF bender and notcher look like? What was the lift looking thing on the garage floor?

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Old 11-19-2007, 12:47 PM   #7
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not really a write up so moving here
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Old 11-19-2007, 12:54 PM   #8
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Can you show what the HF bender and notcher look like? What was the lift looking thing on the garage floor?

-
Check out the Harbor Freight site...they have good pics on most of their tools. The lift lying on the floor is either a motorcycle or a RV lift. Great item to have if you're when you're fabbing steel. A neighbor built his T-bucket frame on one in his garage.
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Old 11-19-2007, 01:05 PM   #9
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What'd you use to bend the cage?
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Old 11-19-2007, 01:49 PM   #10
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Old 11-19-2007, 03:49 PM   #11
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thats awesome!
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Old 11-19-2007, 04:41 PM   #12
The Bucking Bronco
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Answers:

Yes I am putting a warn winch on it (hopefully today)

The lift is a bendpak scizzor lift capable of lifting 6000 LB It lifts the bronco with no problems


I have a jd2 bender for the cage

I will post some more pics along with the bender, notcher and winch later when I get it all mounted up

Here is a pic of the bronco on the lift it actually goes about a foot higher but with the garage door open i cant lift it that high

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Old 11-19-2007, 04:56 PM   #13
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That is pimp, man I wish I had one of those@!
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Old 11-19-2007, 04:57 PM   #14
The Bucking Bronco
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I just noticed the bender is in that pic on the bottom right

and that lift is one of the best purchases i have made
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Old 11-19-2007, 05:49 PM   #15
rightofway
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with that lift would you be able to pull a tranny or oil pan or would you end up using the lift to set the truck on high stands?

also:
hmmm, seperated at the drawing board?

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Old 11-19-2007, 06:25 PM   #16
The Bucking Bronco
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not the tranny but easily the oil pan
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Old 11-19-2007, 07:08 PM   #17
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holy crap i want your lift... kudos on the cheap simple bumper... i probably wouldn't bust out the jd2 to do those minor bends either
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Old 11-19-2007, 11:10 PM   #18
The Bucking Bronco
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just got everything completed

Here is a couple pics that were requested







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Old 11-19-2007, 11:48 PM   #19
rightofway
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nice, looks awesome
anymore details on how you mounted the winch?
i saw the hitch mount in the first pic did you integrate that somehow or is the winch plate welded directly to the bumper?
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Old 11-20-2007, 12:33 AM   #20
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Dad gum brilliant!
Very well done, so suprisingly simple.
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