Bumper / Brushguard Build

[lightnin]

I got a ranchand style brushguard from Josh. The plan was to make a bumper the same shape as the brushguard and make the brushguard fit the bumper. Once I picked up this monster I realized it would be easier to make a bumper on the brushguard. It came off of a late 90's early 00's Superduty with the 4 bolt front bumper mounts.

http://www.supermotors.net/getfile/426988/fullsize/100_3567.jpg

http://www.supermotors.net/getfile/426989/fullsize/100_3568.jpg

Cut the steel for the frame adapters. PO bolted it up to the bumper. I want it spaced away a little to give me a platform to stand on when I work under the hood. Like the ranchand bumpers.

Got it laid out how it needs to be welded up.

http://www.supermotors.net/getfile/426990/fullsize/im001729.jpg

As you can see in the pics above I had the gusset on the short side. I decided to put it on the long side figured it would work better there.

http://www.supermotors.net/getfile/426992/fullsize/im001736.jpg

Word of advice that I learned about after welding the first one up. Clamp the plate down to the table. My first one drew the 3/8" plate up a little. Not enough to worry about making another one. Once I get it on the frame I am going to weld the plates together anyways. The only way this is comming off my bronco is if the frame comes with it. :toothless


List for the brackets

2 - 4"x12" 3/4" plate
2 - 4"x9" 3/8" plate
2 - gussets cut from a 3.5" flat 1/4" steel

Cost 0.00 so far for the mounting. Scrap steel at work and a welder at work.

[Blanco]

Looking good Dooode !! :m2c:
I cant wait to see this thing when you get it driveable ..:spaz_smilie:
& start driving it regularly I've only seen it on jack stands till recently..:rolleyes:

[lightnin]

Yeah about that. I have a guy or 3 interested in my Solid D44 so I am hopeing to sell it. So back on jackstands it goes and in goes a D60 wahoo.

[Red Wagon]

ya its funny...you dont think that you could warp 3/8's steel...but some heat to it and off it goes.

[lightnin]

Got the brackets finished and bolted to the guard and semi attached to the frame.

http://www.supermotors.net/getfile/426995/fullsize/100_3581.jpg

http://www.supermotors.net/getfile/426994/fullsize/100_3582.jpg

And here she is.

http://www.supermotors.net/getfile/426999/fullsize/100_3577.jpg

http://www.supermotors.net/getfile/426996/fullsize/100_3608.jpg

[Blanco]

HOLY approach angle killer Batman! :eek:

[lightnin]

Screw approach angle. With this bumper I can push it out of the way or bounce over it. lol

[Blanco]

Screw approach angle. With this bumper I can push it out of the way or bounce over it. lol
:4:

[lightnin]

We will start with the recovery points.

1 peice of 1x2 steel about 7" long or so. It was in scrap iron. Round the edges with our new plasma cutter and grind them down the best I can.

http://www.supermotors.net/getfile/436984/fullsize/im001837.jpg

An idea on were to place the clevis ring.

http://www.supermotors.net/getfile/436985/fullsize/im001838.jpg

Mark and punchmark where you want to drill. Rig up a jig (ie. Clamp it to the table)

http://www.supermotors.net/getfile/436987/fullsize/im001839.jpg

Bust out the new Milwaukee drill with the new 1" steel Hawg bit.

http://www.supermotors.net/getfile/436986/fullsize/im001840.jpg

http://www.supermotors.net/getfile/436988/fullsize/im001841.jpg

Start drilling.

http://www.supermotors.net/getfile/436989/fullsize/im001842.jpg

What the Steel Hawg does to mild steel.

http://www.supermotors.net/getfile/436993/fullsize/im001843.jpg

Test fit looks good. Flip it around and do it again.

http://www.supermotors.net/getfile/436991/fullsize/im001845.jpg

After drilling both sides cut it in half.

http://www.supermotors.net/getfile/436994/fullsize/im001854.jpg

Next move on to the bumper center section. I went with 6" schedule 40 to save weight over the 1/2" mill channel center section. Cut to length to fit between the brushguard legs. Eyeing the recovery point.

http://www.supermotors.net/getfile/436995/fullsize/im001846.jpg

http://www.supermotors.net/getfile/436995/fullsize/im001846.jpg

http://www.supermotors.net/getfile/437002/fullsize/im001853.jpg

Next I laid out the holes for the recovery points and Plasma'd them out. A good steady hand is required for this. I don't have one as you can tell. lol

http://www.supermotors.net/getfile/437570/fullsize/im001855.jpg

Did a little better on this one.

http://www.supermotors.net/getfile/437569/fullsize/im001856.jpg

Test fit the recovery point. Looks good.

http://www.supermotors.net/getfile/437567/fullsize/im001858.jpg

Time to tack and square it up.

http://www.supermotors.net/getfile/437571/fullsize/im001862.jpg

http://www.supermotors.net/getfile/437572/fullsize/im001863.jpg

Now time to weld it solid. I wanted our fabricator to weld them since they are going to be yanked on.

http://www.supermotors.net/getfile/437575/fullsize/im001868.jpg

http://www.supermotors.net/getfile/437576/fullsize/im001867.jpg

http://www.supermotors.net/getfile/437577/fullsize/im001869.jpg

Got'er welded.

http://www.supermotors.net/getfile/437579/fullsize/im001870.jpg

http://www.supermotors.net/getfile/437581/fullsize/im001873.jpg

Looks good but how good?

http://www.supermotors.net/getfile/437583/fullsize/im001875.jpg

Close enough for me lol.

http://www.supermotors.net/getfile/437582/fullsize/im001874.jpg

http://www.supermotors.net/getfile/437580/fullsize/im001872.jpg

There it is. Just need to weld the recovery points on the inside of the tube. Then take it home and weld it on the brushguard. I think it will look really good. Especially when I get a chance to finish it. I will be going with 4" on the outside of the brushguard legs.

[Blanco]

Looks good :cheers:

I have 2 questons..

1st. are you going to Gusset the inside of the Tube?

2nd. are you gonna use that tube for an Air tank ...

I see it screaming Airtank. :shrug:

[lightnin]

1. No
2. No, Got to thinking about it and I don't want to pull with the recovery points with the tank pressurized. Folks on here will need to discuss their ideas on that.

[Blanco]

Well its easy enough to empty Your air pressure before using the tow points...

Why would you have the Tank Pressured up at that point anyways? :shrug:

one thing I can tell you is a single 5 Gal Tank aint enough..
When I was blowing out Blanco the other day (Trying to get all the dirt & dust from Primm out of the interior I would only get enough tank Prssure for like 6 or 7 second Bust of good pressure then I'd have to let it build up again.

:m2c: What ever its worth..:shrug:

[lightnin]

For me having air when you need it is the puropse behind OBA. I would have air in mine as much as possible. Not having a empty tank and when I need it kick on the compressor. Air on demand.

[Blanco]

That Makes NO sense to me why would you need your tanks etc filled with built up Pressure? :6:

Lets say you actually use your OBA Once a month maybe even two or three times a month if you wheel alot.
You dont have Air Lockers, So I figure most of your OBA will be for tires .
do you really need Your Tanks pressurized all the time in between just in case you find your self needing "Air on demand" ?

& a air dump Valve for draining condensation & such would work for Draining your tank if you ever find your self needing to use your new Tow points.. :m2c:

You do what you want.
I'm not trying to sell you on the idea I just thought it would be nice since how its shaped to use a a tank..

[lightnin]

I understand what your saying. Yes when I have oba and a tank mounted the system will have leaks and I will have an auto drain on it to purge the water out so when I get in it each time more than likely the tank will be empty. But when I start it up the compressor will build up and I will have air. I help people on the side of the road when I get the chance. Instead of changing a flat I just throw in a plug and air it up. there you go now your on your way. I enjoy it alot.

[lightnin]

Got a little more work don on it. After alot of cutting, grinding, testing, and more grinding. The center section is in. Just need a small peice of steel to fill in the back where the tube is a little bigger then the brushguard. But I am very happy the way it turned out.

http://www.supermotors.net/getfile/438052/fullsize/100_4456.jpg

http://www.supermotors.net/getfile/438053/fullsize/100_4451.jpg

http://www.supermotors.net/getfile/438054/fullsize/100_4458.jpg]

http://www.supermotors.net/getfile/438055/fullsize/100_4454.jpg

http://www.supermotors.net/getfile/438056/fullsize/100_4455.jpg

http://www.supermotors.net/getfile/438057/fullsize/100_4459.jpg

http://www.supermotors.net/getfile/438061/fullsize/100_4464.jpg

http://www.supermotors.net/getfile/438064/fullsize/100_4463.jpg

Here you can see how far they stick out the front. I was thinking of mounting the recovery point flush and the clevis would swing out but liked the look of them sticking out a little.

http://www.supermotors.net/getfile/438065/fullsize/100_4462.jpg

http://www.supermotors.net/getfile/438066/fullsize/100_4461.jpg

This pic you can see the gap I need to fill in. I moved the hooks to the outside of the brushguard. Something about Superlift ORV Park says bolt on recovery points not welded. So I have both for now. I think I have 1 or 2 more sets of these hooks.

http://www.supermotors.net/getfile/438067/fullsize/100_4466.jpg

[87BIIXLT4x4]

mmmm beefy

[Blanco]

Looking :awesome_dude:

I fixed one of your Pics that was missing a " ] "

So what you got planned for the Outside of the Brushgaurd part of the bumper? :humm_smilie:

It might look kinda cool just like that, But without the tires on it its hard to say. :6:

It might just look unfinished :shrug:

[lightnin]

It is going to stay like that for now. I need to get my leaf swap done. I am thinking of cutting the fangs off the front of the fenders. Running 4" round outside the legs at a 45* angle and follow the brushguard and flat sock at the end back to under the fender. If that make any sence.

[Blanco]

If I understand you correctly sound Tuff looking. :cooool:

[lightnin]

Thanks cam. What happen on messenger you don't have time for a game?

[83 Toy]

If I understand you correctly sound Tuff looking. :cooool:

:WTF: :6: