Smittybilt Tube Bumper Install - Ford Bronco Forum
 9Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 22 (permalink) Old 12-04-2015, 08:00 PM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Smittybilt Tube Bumper Install

So I have been on the lookout for a new front bumper to get rid of my factory chrome one with pushbar. The front bumper was the last piece of body armor to complete the rig. So I was out at the junkyard looking for a Saginaw bracket and there happen to be a tube bumper that the owner was 'hiding' for himself. After a little talking, he let it go for 40$. Normally the Smittybilt tube bumper for these years broncos do not wrap around the front end.. they just kind of end flush with the fenders. This bumper had ends that went all the way around and was one inch narrower than the factory bumper. I am not sure what it came off of. So.. A little body trimming and leftover steel later.. Bumper installed keeping the factory lines!! I clamped some steel onto the frame, placed the bumper where i wanted and tack welded it to the frame. Then I just replaced the existing bracket with some steel and sandwiched the frame on the other side. The brackets are much stronger than the factory ones and this bumper is surprisingly stout. (I was expecting wimpy chrome nerf bar material) I am going to cut some thick tubing and place it between the two brackets to sandwich the frame and use some grade 8 hardware to bolt it all together. Then all I have to do trim the corners near the tires at an angle to follow the look of a wheel well, cap and weld it and then its good to go. Also this style bumper angles forward and leaves the perfect amount of room for a winch! (time to cut some c channel for a winch plate).

dash_cam and SRWillis like this.
91FordGuy is offline  
Sponsored Links
Advertisement
 
post #2 of 22 (permalink) Old 12-04-2015, 09:13 PM
Use the Force...
 
Darth_ted_82's Avatar
 
Join Date: Jan 2014
Location: Oklahoma
Posts: 961
Bronco Info: 1988 Eddie Bauer; 5.0L AOD; 3" suspension lift w/33x12.50 KOs. '77 F100 Custom, step side, restoring
iTrader: (1)
Looks good! Nice find, man.

'88 Eddie Bauer, '98 5.0L w/GT40p heads, HD AOD, 130A 3G, 3" suspension w/33x12.50KOs, Tow Package.
Porkchop Express' Thread - http://www.fullsizebronco.com/forum/...d.php?t=279266
Blacksheep 2/75
R.L.T.W.
Darth_ted_82 is offline  
post #3 of 22 (permalink) Old 12-04-2015, 09:57 PM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Thank you! Next project is to plate the bottom tube to the brackets for the added strength
91FordGuy is offline  
Sponsored Links
Advertisement
 
post #4 of 22 (permalink) Old 12-05-2015, 12:22 AM
Registered User
 
SteelHorse's Avatar
 
Join Date: Sep 2013
Location: Northern CA
Posts: 468
Bronco Info: 95 XLT 5.8
iTrader: (0)
Looks really good! Clean install! I like the plate idea for increased strength...keep up the good work!
SteelHorse is offline  
post #5 of 22 (permalink) Old 12-05-2015, 01:24 AM
Retired Staff
 
BikerPepe`'s Avatar
 
Join Date: Feb 2003
Location: N.E. WA
Posts: 34,163
Bronco Info: '95 XLT, 5.8/E4OD/MassAir/6" lift/4.56's/33x12.5 GYW DuraTracs
iTrader: (4)
Garage
damn! so jealous! I've got the lighting bumper on the rear of my '90 and would love to stumble across a smitty built.
looks good... you luck dog!
BikerPepe` is offline  
post #6 of 22 (permalink) Old 12-05-2015, 02:05 AM
Fullsize Member
 
Join Date: Jan 2010
Location: S.E. WA
Posts: 674
Bronco Info: 86 XLT w/ 5.0 & WR AOD, factory 4.10's, 31x10.5
iTrader: (0)
Looks good, nice score
Sloride75 is offline  
post #7 of 22 (permalink) Old 12-05-2015, 03:43 AM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Thanks guys, means a lot with the positive feedback!
91FordGuy is offline  
post #8 of 22 (permalink) Old 12-05-2015, 08:27 PM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Alright.. onto the next step. Time for a winch plate. Found some truck frame to some kind of big rig and cut it 41 inches long by 8.25 wide. I left a small lip on the front of the plate to keep some strength and I am going to plate it to the bottom of the bumper. Now the winch will be completely enclosed and protected, as well as contribute to the strength of the bumper mount by combining it with the winch plate. Now the bumper will have 3 bolts to bottom and 2 on the side on both sides of the frame.


My plans are to weld a 4 inch wide piece of chain link I found on the inner bumper and then make a bracket for a warn chrome hause fairlead (not roller style). Then bolt it to the front of the bumper. This way i can run the winch line right in between the tubes!
dash_cam likes this.
91FordGuy is offline  
post #9 of 22 (permalink) Old 12-06-2015, 12:48 AM
Retired Staff
 
BikerPepe`'s Avatar
 
Join Date: Feb 2003
Location: N.E. WA
Posts: 34,163
Bronco Info: '95 XLT, 5.8/E4OD/MassAir/6" lift/4.56's/33x12.5 GYW DuraTracs
iTrader: (4)
Garage
sounds great. I hadn't seen a hause fairlead before. googled it up. looks far more efficient.
BikerPepe` is offline  
post #10 of 22 (permalink) Old 12-06-2015, 10:45 AM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
oh yeah, much more compact and it will offset the black with a little chrome again Pictures on the front connecting plate coming soon!
91FordGuy is offline  
post #11 of 22 (permalink) Old 12-08-2015, 08:34 PM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Do you guys think that this thread should be moved to the build threads? I've installed the winch plate, going to box the front to make it all one piece and going to plate the outer tubes to the brackets for strength. Between installing 97-03 F-150 tow hooks today (pics tomorrow) and installing the fairleads, this is turning into a build !
91FordGuy is offline  
post #12 of 22 (permalink) Old 12-08-2015, 09:06 PM
Retired Staff
 
BikerPepe`'s Avatar
 
Join Date: Feb 2003
Location: N.E. WA
Posts: 34,163
Bronco Info: '95 XLT, 5.8/E4OD/MassAir/6" lift/4.56's/33x12.5 GYW DuraTracs
iTrader: (4)
Garage
builds area is for serious builds, not just "bolt-ons". your still kinda in the middle there bud.
could move it to the fabrication area though, if you're not happy with being a "tech write-up".
BikerPepe` is offline  
post #13 of 22 (permalink) Old 12-08-2015, 09:39 PM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
I'm fine with where it is at.. I just did not know what was considered a build or write up!

Alright got some 97-03 F150 factory tow hooks from the junkyard. The rear bolt goes through the frame and winch plate and the front bolt just through the winch plate (It will be stronger once it is plated). I flipped the bracket upside down so that I gained ground clearance and the hoop fit up against the bottom of the bumper.
dash_cam likes this.
91FordGuy is offline  
post #14 of 22 (permalink) Old 12-09-2015, 01:27 AM
Retired Staff
 
BikerPepe`'s Avatar
 
Join Date: Feb 2003
Location: N.E. WA
Posts: 34,163
Bronco Info: '95 XLT, 5.8/E4OD/MassAir/6" lift/4.56's/33x12.5 GYW DuraTracs
iTrader: (4)
Garage
uh... so when you're done there... how much to ship that up to me.
that's going to be a real nice setup when you get it all finished up. Solid work!



build would be a serious and on-going project with your rig.
looks like you've already got a lot done.
Nothing saying you can't make one... but read a few others and get a better idea.
This is great write-up material though.

Last edited by BikerPepe`; 12-09-2015 at 05:58 AM.
BikerPepe` is offline  
post #15 of 22 (permalink) Old 12-09-2015, 09:23 AM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Thank you! Shoot if anybody finds a smitty like the one I did, there should be no reason not to reciprocate this! It is so simple.

And good to know about the differences.. I think ill stick to write ups and keep the projects short and sweet instead of on-going
BikerPepe` likes this.
91FordGuy is offline  
post #16 of 22 (permalink) Old 12-31-2015, 10:10 PM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
So I just got a Warn Hawse Fairlead


I am going to just use a universal fairlead mount and trim it so it fits flat against the front of the bumper and weld it to the lower tube so it places the fairlead opening even with the space between the upper and lower tube.
91FordGuy is offline  
post #17 of 22 (permalink) Old 01-09-2016, 04:37 PM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Alright I finally got around to doing the fairlead mount. I just found a generic fairlead mounting bracket and cut it to the shape of the front bumper and welded it up.
91FordGuy is offline  
post #18 of 22 (permalink) Old 02-01-2016, 08:54 AM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Just got some cool shots of the bumper accumulating some snow
BikerPepe` likes this.
91FordGuy is offline  
post #19 of 22 (permalink) Old 09-01-2016, 04:07 PM Thread Starter
Registered User
 
91FordGuy's Avatar
 
Join Date: Jul 2011
Location: Moorpark, California
Posts: 265
Bronco Info: 1981. 4 inch lift w/35s. Built 300/T-19. Sliding Windows. Custom Front and Rear Bumpers.
iTrader: (0)
Garage
Thought I would update the bumper build.. never needed auxiliary lighting in California but its quite a bit darker on the roads in Colorado and I have needed more lighting on the trails coming home after an evening of fishing.

Welded up some tabs:


And done!
BikerPepe` and biggum like this.
91FordGuy is offline  
post #20 of 22 (permalink) Old 09-02-2016, 12:23 AM
Retired Staff
 
BikerPepe`'s Avatar
 
Join Date: Feb 2003
Location: N.E. WA
Posts: 34,163
Bronco Info: '95 XLT, 5.8/E4OD/MassAir/6" lift/4.56's/33x12.5 GYW DuraTracs
iTrader: (4)
Garage
BikerPepe` is offline  
Sponsored Links
Advertisement
 
Reply

  Ford Bronco Forum > Bronco Discussions > Technical Write Ups

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ford Bronco Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself. DO NOT USE Gmail.com accounts. If you only have a Gmail.com email please contact the administrator here

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome