Rear bumper finished.

Got the box all finished up and ready for paint.








Got the lights marked for cutting. At this point I'm also trying to figure out how to latch everything together. We were going to incorporate a box in the bumper, but ran out of time. Maybe I'll come back and do that later (yeah right).








This is what I came up with for a latch. Trying to keep it really simple yet secure. One bolt holds everything together and also allows the weight to be distributed.






Time to box in the bumper ends. We thought about hinging these as well, but decided not to because of having to deal with all the wires inside of the bumper. Another maybe later project.






Here is a shot of my Dad laying down a coat of primer. He is the real reason my projects turn out so nice.






Here is the finished "latch". Two feet rest on a piece of plastic (chopped up cutting board). Just unscrew the yingyang symbol and both racks swing out. The tire side clears the bumper, but unfortunately the box side scrapes. I'm sure there will be a curved scratch in my bumper soon.






I love the way the ends came out. Looks like we really knew what we were doing.







Finished product. I really love those LED lights.

Building a new rear bumper

I just can't leave well enough alone. The new tire size is way too big to hang on the stock tire rack. I need a way to carry a spare. Being way to cheap to buy a fancy bumper for 3000 dollars I decided to buy a plasma cutter and some steel to try it myself. Yes this chunk of steel is a bit on the GIANT size, but hey, it was 25 bucks.
With the new higher bumper mounting the tow hitch was almost 4 inches lower. After a lot of hemming and hawing, we (Dad and I) came up with raising the tow hitch and then using it to help support the bumper. We were also able to trim the bottom of the tow hitch to improve departure angles.
Bumper hanging by two bolts. Already starting to look not so huge.
Decided to build the other parts before getting too carried away with the bumper finishing. This is the lid to a 28x28x12 storage box. This is our brake, not sure how to spell it, but it's our version of the machine that is used to bend metal. I used the plasma cutter to cut all but small pieces on the bend. Almost making it like a hinge that will bend easy. Hard part is coming back and filling all the holes with weld, then grinding it off.
Box made in two pieces folded at the short corners then welded. Having a heck of a time trying to finish the welding without warping everything. It won't be perfectly straight, but I'm not telling.
Rough draft done. Made a half inch square frame on the inside to keep the square, and have a surface for a seal.

Took me most of the day to make this simple basket on the lid. Probably another few hours just to grind off all of the excess welding.++

Tire rack is coming together now too. We also found a cool way to make both parts swivel. More pictures coming soon.

Maybe a solution to the ABS problem

I recently learned that the abs sensors from the 05 superduty front axle are not compatible with my van. It appears they changed the sensors in 05 to a new kind. My solution is to purchase new ones for a 99-04 superduty 4x4 front axle and replace mine. At the dealer they go for 168 each. I found one on ebay for 50 shipped and talked the dealer down to 125 with next day availability. Not sure how difficult they will be to change, but it doesn't look good. I sure hope this fixes the problem.
UPDATE:
Sure enough. The new sensors work like a charm. Thanks very much to Craig at Salem Kroger for helping me with this one.
I added a picture to show where the ABS sensor is located. That is the sensor with the blue dot in the picture. Remove the wheel, brake assembly, and rotor for access. I was very relieved to have another gremlin behind me.