Rept's Super Slow Re-Re-Rebuild (90) - Page 7 - Ford Bronco Forum
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post #121 of 180 (permalink) Old 04-11-2019, 02:53 PM
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Looks great!!
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post #122 of 180 (permalink) Old 04-14-2019, 11:57 AM Thread Starter
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Thanks guys

Considering its a brick nose, i feel like it needs this beefy bulky bumper up front, as opposed to tubing. I think it fits the body lines better. So i guess thats what im building


So Friday i got a little bit of work done. Made all 4 tabs to laminate the shackle mounts.


I need to pilot them, and then they can be welded up like i did the rears; hopefully Monday. Apparently a month or so ago i forgot to turn the gas bottle off on the mig, so i gotta go get gas tomorrow morning first

Heres a teaser for the corner:
There will be two more pieces to wrap around the corner , and i think im going to change the shape of this one a bit, as im afraid its going to end up too wide. It does give you a good idea of the look im going for though!


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post #123 of 180 (permalink) Old 04-14-2019, 01:16 PM
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I agree, it will be too bulky. I did a taper on mine and then radiused it to follow the wheel opening. Not trying to hijack your thread, just giving you some options.









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post #124 of 180 (permalink) Old 04-14-2019, 01:38 PM Thread Starter
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The shape im going for is similar to yours. Ill be adding the angled bottom piece which will taper up into the corners, and will probably cap the ends similarly as well:




Im looking at two additional angled pieces to make that corner (its not going to be rounded like the cardboard appears), altho once i cut that piece friday, it looked a lot bigger in steel than cardboard. Ill probably make them, and then if it looks too big i can always trim them down a bit. 8' is barely enough to make the bumper, so i cant waste any material or ill have to go back to the steel supplier and order more.


Keep im mind, i will be adding a tubular brush guard on top to protect the grill/lightbar.


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post #125 of 180 (permalink) Old 04-20-2019, 11:45 AM Thread Starter
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Man, the flu! We both got sick last weekend
Thankfully the little guy did not get it.


So really only got the shackle tabs done, nothing else









Both are done now, so ill start working on the corners again on Monday. I do think it needs to be narrowed a bit, i guess we'll find out soon enough!


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post #126 of 180 (permalink) Old 04-22-2019, 04:01 PM Thread Starter
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Got the corners pieces cut & tacked into place








Everything is straight, except for the sheetmetal Ill have to adjust it a bit once i get the bumper 100% done.


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post #127 of 180 (permalink) Old 04-22-2019, 08:19 PM
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Love it - nice work! I think itís perfect.


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post #128 of 180 (permalink) Old 04-24-2019, 04:10 PM Thread Starter
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Thanks


So i got some work done to the driver side:









Finally, its all tacked together

In case you were wondering, this is all thats left of that 8' piece:


3ľ". Just made it


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post #129 of 180 (permalink) Old 04-24-2019, 11:40 PM
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nice work man. dig the tip angles. gotta love it when materials work out so tight.
that's going to be one of the cleanest looking winch bumpers I've seen in some time.
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post #130 of 180 (permalink) Old 04-25-2019, 08:49 AM Thread Starter
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Thanks Pepe!

Weve still got a ways to go before its done, but im pretty happy with it thus far.


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post #131 of 180 (permalink) Old 04-26-2019, 04:50 PM Thread Starter
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An old friend stopped by to catch up today, so not much progress. But thats ok, because i dont have the steel to continue. So i did some mockups in cardboard, this is what im thinking:









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post #132 of 180 (permalink) Old 04-27-2019, 07:45 AM
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Looks good; I like the cardboard mock up but think the angle should be a little tighter. (raked more towards the back) Either way, it's coming out awesome!

Maybe something more like this?



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post #133 of 180 (permalink) Old 04-27-2019, 10:05 AM Thread Starter
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The pics dont show it well, but it is laid back 45ļ. I can experiment with making it steeper though on monday after i get some plate.


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post #134 of 180 (permalink) Old 04-27-2019, 02:47 PM
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post #135 of 180 (permalink) Old 04-27-2019, 09:12 PM
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You definitely have some monster garage stuff going very cool metal work.
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post #136 of 180 (permalink) Old 04-28-2019, 08:16 AM Thread Starter
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Two votes to change it, so il guess ill look into it tomorrow, see what i can come up with


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post #137 of 180 (permalink) Old 04-28-2019, 09:24 AM
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I donít agree, I think the way it is carries the line down from the wheel opening well and then turns forward to tie into the bottom of the bumper.


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post #138 of 180 (permalink) Old 05-02-2019, 09:08 AM Thread Starter
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So i tinkered a bit, this is what i came up with. Its very similar to what i had originally, just some minor changes to the corner to tighten it up a bit:

4" across the bottom, the angled pieces taper up to 3"


...and from there tapers again...

...until the corner, which ends at 1".


Pretty tight to the body


The end is capped, and i added a bent piece in the bottom to add rigidity to the corner.


Im pretty happy with this, i think its going to work out well. Now i need to duplicate it on the other side!

I still need to add gussets from the bumper brackets, add a tubular brush guard, mount the light bar, cut the opening for the winch fairlead, and then do an absolute ton of welding!


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post #139 of 180 (permalink) Old 05-09-2019, 10:40 AM Thread Starter
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Finally, an update!

I got the driver corner finished





I knew i was going to be doing some tube work, so i ordered some stuff, and took a couple days to upgrade the bender:


New base with swiveling locking castors, and a hydraulic conversion courtesy of SWAG Offroad
Just in case i might ever want to switch back to manual for some dumb reason, i added 1/2" holes to bolt it to the floor, and the castors are bolted in place via tapped holes in the base plate.
It is soo much easier to use than by hand! Wish i did this years ago, makes bending tube so much easier to do by myself. No spring-back on the bends either, which is a huge plus over manual bending. So with that done, lets bend some tube!



Monday i took some measurements and got the main hoop bent and tacked in place:




..and then bent up some side bars yesterday:










Man, i am super excited with how this thing is coming out!!Hopefully tomorrow ill be out there working on it again; i want to add some gussets to the bumper brackets, and then im going to start welding up all the seams

At some point, the bumper needs to come off so i can mount the winch, and then lay out the window ill need to cut for the cable to come thru. We're getting close to completion on this thing!!!
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post #140 of 180 (permalink) Old 05-09-2019, 03:34 PM
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What's your technique for shaping the ends where the tubing meets? Just lots of grinding and checking? I just did some of that and found it to be slow going, with imperfect results.

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