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ate lug
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8,450 Posts
Discussion Starter #141
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.

I usually just eyeball it :toothless

The center hoop, i have a jig for cutting the angles on that one, that i built years ago when making tube steps for a quad-cam ram. So i just set the hoop in there, and adjusted it til the angle was right. So no real thinking involved in that one.
The two on the end, one is a mirror image of the other. The first one was the driver side; i eyeballed it and cut it, and was damn near on in the first shot. The bottom end needed a second cut, the top end just needed some minor grinding. Then bent the second, copied the angles over to it, and mirrored them. I wish i could say theres more to it, but not really. Its just that ive done it a couple times before, and already knew roughly what theyd look like when cut. Ive used the paper trick before and it works pretty good, but not on such a heavy angle like the top has. You can get contour gauges that get you pretty close pretty quickly as well, but theres definitely an art to it i think. Usually i can get it pretty close on the first shot, but ive also made a lot of mistakes on cuts over the years too :toothless No angle finders; i find it easier and quicker to just eyeball it, and do some minor grinding if need be.

All that said, i spent probably an hour on those two pieces, but that does include setting up the smaller die in the bender. Once i had the shape, the second went quickly.



I bought one of these (carbide tipped sawzall blade), which has been a huge help in building the front bumper. Yes only one, and yes its still going strong. It seems its going to last forever, and makes nice straight cuts quickly.
 

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ate lug
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8,450 Posts
Discussion Starter #143
Bumper progress!

Gussets for the bumper brackets:


I decided on two for each side. While im sure one would probably be sufficient, it just looked out of place with one, and i figure a second cant hurt.





Time to weld those seams!


...and more welding....


...and more welding!


So if all goes well, ill be removing the bumper wednesday to begin grinding all the seams and getting them cleaned up, then lots more welding & grinding after that :toothless
 

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ate lug
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8,450 Posts
Discussion Starter #145
Man, aint that the truth :banghead



So i did some minor grinding with the bumper on the truck, just enough so i could fit and tack the smaller tubes in place. Then, off she came!



Set up on my cart, outside in the sun, grinding away!


This part is gonna take a while :uhoh3
 

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MidlifeCrisisUndrWay
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1,613 Posts
Looking good! :beer
 

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ate lug
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8,450 Posts
Discussion Starter #150
Welding is basically done :cool:





Mocking up window for fairlead
















This Powerwagon winch has an usual handle (it was also cut down at least once before i got the winch). It also doesnt clear the bumper.


Pulled the winch apart to modify handle, as i dont want to cut a notch on the bumper. The inside is nice and clean, and recently greased too


i straightened the handle and reassembled to mock up


Then bent a 90º in it in a different place. This is freespool...


...and this is lock




...and done!



Tomorrow im going to do some touchup on a couple welds & corners, then pull the cap back off the winch to reseal it (it still needs rtv on it). Then ill throw the whole thing back on the bronco for some proper 'finished pics' :cool:
 

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ate lug
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8,450 Posts
Discussion Starter #152
Thanks :thumbup

Honestly probably just going to be semi-gloss black. The truck will be Magnetic or something similar, with all accents (flares, door handles, all trim, etc) black, so i think the bumpers will look better black rather than color. Im currently debating powdercoat, or just painting them myself. I feel like blasting, plus PC on both bumpers will be pretty pricey.
 

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Premium Member
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34,846 Posts
PC ain't cheap and as much as I love it... I'm coming around to the idea that a DIY bed-liner or similar product is far easier to repair when needed. You're not generally a "street queen" kinda guy, so that's something to consider. I always wonder if that "Hammerite" stuff is actually worth a damn.

Thing looks awesome and I dig the little mod on the winch switch over butchering your beautiful new bumper. I caught some chrome flaking off of mine during the last car wash and immediately thought of yours. One of these days. :thumbup
 

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Registered
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1,732 Posts
Bumper looks great. Take a look at rustoleum rattle can bedliner. I use it on all my black bumpers, cages etc. Matte finish, not semi and not flat. Has a nice fine texture to it. Cheep, easy to revolt, and a little tougher than regular paint.


Sent from my iPhone using Tapatalk Pro
 

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Ford-a-Holic
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3,918 Posts
I agree, after powder coating many car chassis (probably 35+) I'd paint over powder coating, especially on a 4WD. Powder coat can chip or crack and once it does, it acts like egg shell that you can pick away and peel. (think power washer) If exposed to UV, the color tends to fade and once it chips, it's impossible to touch up. If you do go the PC route, BE SURE TO SANDBLAST YOUR BUMPER FIRST. They may tell you it's unnecessary and that you get good adhesion without it, but trust me, I have had them done over raw steel and it just doesn't last.

Good luck either way.
 

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ate lug
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8,450 Posts
Discussion Starter #156
I guess ill paint then :toothless

I was concerned about the PC chipping, but also figured itd be easier to paint, if im not the one doing it :toothless

I was worried about bed-liner peeling off from a rock and not begin able to touch it up properly, i suppose its the same for PC.

Ill have to run out and get some cleaner and primer for next week; id love to have them both totally done in the next week or two so i can move on to the next phase of this project!
 

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Another vote for painting. Depending on what access to materials / tools you have, I vote base coat / clear coat. I've done a few frame off's and helped with several more. A good epoxy primer on the frame, followed by a decent base coat / clear coat (you could get go matte or use flattener in the clear if you like) is much more durable (in my opinion) than powedercoating on a vehicle that gets DRIVEN.

Based on having access to the pieces being sprayed is the key of course. Otherwise there are several good products out there than can be brushed on and most importantly - can be EASILY and cheaply touched up as needed.

Powder coating (at least in my opinion) is VERY sensitive to the part being stripped totally clean as well.
 

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1,874 Posts
Im estimating 125 lbs w/o the winch. My 42s (mounted on beadlocks) are 170#, its definitely not that heavy. If i can, im going to (carefully) get both on a scale and see :thumbup
That's not too bad of a weight penalty. Off-road bumpers have a reputation of being a lot of extra weight, but looking at the finished pics, I figured it has to be under 150 lbs. I never weighed the stock bumper when swapping to the vented style. I'm thinking that was in the 40-50 pound range, but my memory may be way off. Yours may be only 80 lbs heavier.
 
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