Orgasmic Farmer Posted September 12, 2006 Share Posted September 12, 2006 Having finally bent the standard bumper once too often and left the end caps hanging at rediculous angles after our last foray into the woods, I finally decided to do something with all the odd bits of steel lying round the workshop. Also gave me a chance to practice on the old welder. I wanted a bumper that didn't look too dissimilar from the original but it needed to be very strong. Starting point was to cut off the old brackets, weld a 6mm plate onto the inside edge of the braket (to add strength) and then weld a 8mm angle btween the 2 brackets. The angle was bent in the middle to follow the curve of the old bumper. To this I welded a 3mm 2x3 box, also cut on 3 sides and re-welded to give the curved shape. I then fored the corners by cutting and re-welding the box and then added extensions to mimic the form of the old bumper. I then added 6mm gussets below the bumper to brace it in the vertical plane and to give it more visual depth. These are angled back to help with the approach angle and are fixed to small pieces of box that form high-lift jacking points. The central bit between the jacking points was in-filled in a similar way. Finally I added some bracing to add stregth to the corners and to triangulate the side pieces. The whole lot was welded up and tidied up with the grinder. Here it is fitted to the truck prior to painting And another pic showing the high-lift in operation (using the standard bit not the defender tube fitting). I ran a few beads of weld inside the box where the jack locates to help stop it sliding off. Now all I have to do is paint it up. More pics will follow when its finished. Mark Quote Link to comment Share on other sites More sharing options...
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.