Basic fitting. The goal is to make something that will provide protection, mount the winch, look good, and maybe even have some storage. Started with this 3/8 inch 6x6 for the main mount. Added some 1/4 inch 4x3 for the front.
Big chunks cut down and mounted. Good solid platform for winch tugging since the winch is bolted to the big iron.
Hmmm, can I fit this big clunky roller fairlead right here. Eventually did, but should have made the vertical higher at an angle to keep it all flush. Maybe I'm glad we didn't though, had enough crazy angles to deal with as it was.
Fitting box around the winch. Where to put hinges, how does it open, will the winch be able to clear in and out? Spent a lot of time trying to allow for air flow behind the bumper.
Basic mounting and middle finished. Now trying to figure out how to build up the ends.
Oh that helps. Make a rough outline out of cardboard. I'm usually too impatient for this, but really had not choice for this build.
Just started building out from the middle. Making duplicate pieces to keep each side the same (mostly). Made the bottom and back first then "skinned" the front and top last.
The shapes just got less and less square the farther out we went. Notice the piece on the floor which fills the bottom tip of the bumper. No more square angles left on the outsides.
All tacked together and now trying to weld it up without warping everything. There are over 40 individual pieces. Guessing over 150 feet of welding.
This is the best it ever looked. All shiny with the welds showing it looked really cool. We kind of screwed up on the paint so may have to re-do it.
Ready for primer. See the front receiver hitch. I weighed the bumper at this point. 144lbs.
Final paint drying. Looks like a cross between transformers and road warrior. It took two of us old farts 6 days at least 8 hours a day to do this. Total cost was only around 300 bucks. Was it worth it, yes and no. Love spending this kind of time with my father, don't love all the work involved or lost time.
Basic fitting. The goal is to make something that will provide protection, mount the winch, look good, and maybe even have some storage. Started with this 3/8 inch 6x6 for the main mount. Added some 1/4 inch 4x3 for the front.
Big chunks cut down and mounted. Good solid platform for winch tugging since the winch is bolted to the big iron.
Hmmm, can I fit this big clunky roller fairlead right here. Eventually did, but should have made the vertical higher at an angle to keep it all flush. Maybe I'm glad we didn't though, had enough crazy angles to deal with as it was.
Fitting box around the winch. Where to put hinges, how does it open, will the winch be able to clear in and out? Spent a lot of time trying to allow for air flow behind the bumper.
Basic mounting and middle finished. Now trying to figure out how to build up the ends.
Oh that helps. Make a rough outline out of cardboard. I'm usually too impatient for this, but really had not choice for this build.
Just started building out from the middle. Making duplicate pieces to keep each side the same (mostly). Made the bottom and back first then "skinned" the front and top last.
The shapes just got less and less square the farther out we went. Notice the piece on the floor which fills the bottom tip of the bumper. No more square angles left on the outsides.
All tacked together and now trying to weld it up without warping everything. There are over 40 individual pieces. Guessing over 150 feet of welding.
This is the best it ever looked. All shiny with the welds showing it looked really cool. We kind of screwed up on the paint so may have to re-do it.
Ready for primer. See the front receiver hitch. I weighed the bumper at this point. 144lbs.
Final paint drying. Looks like a cross between transformers and road warrior. It took two of us old farts 6 days at least 8 hours a day to do this. Total cost was only around 300 bucks. Was it worth it, yes and no. Love spending this kind of time with my father, don't love all the work involved or lost time.
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3 comments:
I am looking to make a rear bumper for my excursion. What thickness was the steel you used for the front? I saw the 6x6 piece of anlge was 3/8", but what about the rest?
Hey I'd like to say thanks for posting your conversion. I have an 04 that I've picked up an 05 F250 front end and transfer case from as well. I however am useing a Fabtech four bar lift kit. I will be checking back to see if you've made any progress on the ABS issue.
Dan
Wow, super job Tom! I know about the too impatient part when you mocked it up with the cardboard. Turned out really nice. What's next the turret for the 50 cal on top of the tank? lol!
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