24-Jan-2015
I came up with a final length and cut the piece I need
Although 1/4" wall 2" x 5" tube is a little heavy, I have an idea to get the weight down.
24-Jan-2015
Bumper material weight
The front bumper material is 5" x 2" x 1/4" wall 42" long rectangle tube. I got a good deal on a 10' piece of this material so it was hard to pass up even though it wasnt the 3/16" thick material I was looking for. I'm hoping to cut this weight way down with my design. Although 38.6 pounds isn't really heavy, it's heavier than I want it to be.
25-Jan-2015
Front bumper design laid out
After measuring numerous times I finally came up with a design that I could make work. I don't want a front bumper that sticks out the sides too wide and I didn't want a bumper that was just a wide piece of tube, that would be too easy and I want something a little different.
25-Jan-2015
Excess material removed for design
I used the plasma cutter to shape the bumper to the design that I had drawn up.
25-Jan-2015
Almost all welded up!
After cutting my design shape I had to weld all the pieces bad together. The end caps still need to be cut and welded on.
01-Feb-2015
End caps on and welded complete
I made the end caps and completed all the welding and then hit the whole bumper with a fine flapper wheel. Then I laid out the design and material removable on the back.
25-Jan-2015
Flush mount dualies
The bumper will house some flush mount LED lights for added driving light.
01-Feb-2015
All machining complete on backside of bumper
I removed quite a bit of steel from the backside of the bumper.
01-Feb-2015
Machining complete
After using the plasma cutter to remove the bulk of material from the backside of the bumper, I took it to a friends house to use his mill and clean up all the cut edges. My brother, who's original trade was a machinist gave my the tooling that I needed to complete this job.
Although I don't use a mill very often and I was a little rusty, it came out prtetty good!
04-Feb-2015
Weigh in after all machining is complete
The weight of the bare bumper is now 23.1 pounds. I knocked 15.5 pounds off the weight! I still need to weld on the mounts but I made a substantial weight reduction.
05-Feb-2015
Almost there!
After cutting a 12° section out, heating the front t a red hot, then welding it back together I ended up with a 24° end section on both sides.
07-Feb-2015
Light guards welded in place
After bending the LED light guards I welded them in place. These "should" give the LED lights a little protection from rocks and Hi-Lift jack.