Full Size Ford Bronco Forum banner

1 - 20 of 27 Posts

·
Registered
Joined
·
274 Posts
Discussion Starter #1
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).

 

·
Registered
Joined
·
274 Posts
Discussion Starter #3
Thank you! Next project is to plate the bottom tube to the brackets for the added strength:thumbup
 

·
Registered
Joined
·
274 Posts
Discussion Starter #8
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!
 

·
Registered
Joined
·
274 Posts
Discussion Starter #10
oh yeah, much more compact and it will offset the black with a little chrome again:D Pictures on the front connecting plate coming soon!
 

·
Registered
Joined
·
274 Posts
Discussion Starter #11
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 !
 

·
Registered
Joined
·
274 Posts
Discussion Starter #13
I'm fine with where it is at.. I just did not know what was considered a build or write up!:shrug

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.
 

·
Premium Member
Joined
·
34,623 Posts
uh... so when you're done there... how much to ship that up to me. :toothless
that's going to be a real nice setup when you get it all finished up. Solid work! :beer



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. :thumbup
 

·
Registered
Joined
·
274 Posts
Discussion Starter #15
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:toothless
 

·
Registered
Joined
·
274 Posts
Discussion Starter #16
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.
 

·
Registered
Joined
·
274 Posts
Discussion Starter #17
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.
 

·
Registered
Joined
·
274 Posts
Discussion Starter #19
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!
 
1 - 20 of 27 Posts
Top