Project: Cheap Rear Bumper

[Quick Draw]

Well, my garage is filled with scrap steel, yet again. This time, I'm doing a rear bumper.

The design is pretty basic. Those of you who have seen Fondigley's rear bumper, I'm shooting for something similar, without all of the fancy metalwork. I'm going to clearance the bed, and wrap 2x4x.120 square tubing around it. I will then retrofit my current 2" receiver hitch into the bumper, along with D-rings for shackles....all the while reinforcing and gusseting the crap out of it....of course.

While I kind of kept my slider project to myself...maybe a little stubbornly... I'd like to involve TTORA in a few aspects.

First, I could probably use the help of somebody with a plasma cutter, that can cut a nice clean hole for the receiver. I might also need that to cut apart the hitch to begin with.

Second, I could use the help of somebody to clearance the bed. Preferrably, somebody that has done it before, with good results. I mean, I can hack sheetmetal.....but a hackjob isn't what I'm going for.

And now, I need some ideas for how to tie into the frame, with bolts to make it removable.

This project is in the future, so don't expect to see progress pics for a little bit. I just ordered a body lift that needs to go on first.

[Avsfreak1234]

kyle, if you have access to a program like solidworks or catia I have a few bumper designs exactly like that done up already because thats the design Ive wanted to go with for a while, I just dont have any $$ for scrap steel until a few other projects are done. Id love to help with it but dont have any of the tools you might need. let me know if you do want some extra hands or some designs.

[Quick Draw]

I don't have those programs, unfortunately. As far as the bumper goes, I don't need a whole lot of design work, other that the way I tie it into the frame. It's pretty much just going to be square tubing with 90 degree angles, and somewhat of a hypotenuse on the inside to strengthen the sides. I'll do my 45 degree cut and cap like I did on my sliders to the ends.

If you'd like, you can absolutely help out with the bed clearancing and such. Maybe Nate can help out, and we can get a TTORA members without the privelage of (legally) drinking party going. Haha.

[Avsfreak1234]

I don't have those programs, unfortunately. As far as the bumper goes, I don't need a whole lot of design work, other that the way I tie it into the frame. It's pretty much just going to be square tubing with 90 degree angles, and somewhat of a hypotenuse on the inside to strengthen the sides. I'll do my 45 degree cut and cap like I did on my sliders to the ends.

If you'd like, you can absolutely help out with the bed clearancing and such. Maybe Nate can help out, and we can get a TTORA members without the privelage of (legally) drinking party going. Haha.

sounds like a sweet idea! any chance you have extra 2x4 and we could make two bumpers and clearanced beds:D

[Quick Draw]

I've got 16 ft....It's likely.... Let me take some measurements. I might have to get some more scrap, just for the mounts, but I think we could do it.

[AxleIke]

If you cannot get the plasma cutter (which would certainly be the best way) I did my reciever with a cut off wheel on a 4.5" grinder. It worked really well, and is very strong, you just have to weld a little more, but not much. Its very easy.

Second thing: Do you have a hitch currently? If so, that is a GREAT starting point for the bumper mounts. They are designed to take a lot of weight, so you can cut the mounts off, so that they don't hang down below the bumper, and then tie your bumper into those. The bonus is that they are already custom cut for your frame, so its just a matter of attaching the bumper. Super easy.

[Quick Draw]

Yeah, I want to do something very similar to your bumper. That's where I came up with the idea for the receiver inside a 2x4 square tubing.

Good idea, with the hitch mounts... I'll have to get under there and see how that would work.

[Well-Strung]

Id love to join in and see some of this hacking. Im debating the same type of wrap around simple sheet steel bumper... clearanced. Sure would be nice to see it happen first.

[Avsfreak1234]

I've got 16 ft....It's likely.... Let me take some measurements. I might have to get some more scrap, just for the mounts, but I think we could do it.

if you have some extra for one for me id even pay you for it:eek: then we could build yours first to make all the mistakes on it, learn from those and make one that looks better and is a lot stronger for me :D

[Well-Strung]

why not just build a half a dozen or so huh guys...lol

[Quick Draw]

if you have some extra for one for me id even pay you for it:eek: then we could build yours first to make all the mistakes on it, learn from those and make one that looks better and is a lot stronger for me :D

Lol I hoped that you would toss a couple bucks my way for it. I bought too much and I was going to have to sell some back. But I won't screw you over. Honestly, I paid a little more for this stuff than I did for the sliders... About $5 a foot. 8ft is $40, but also there's welding rods, and the other materials to mount everything, so I would call $40 fair... Less than I'm paying for the same thing for sure.

[Quick Draw]

why not just build a half a dozen or so huh guys...lol

Hell, I would do it. If enough people trusted me to weld and fab their shit, I'd quit my job and go into business... I'm pretty new to the whole fabrication thing though, so I don't think that's going to happen. Plus when people find out they paid a 17 year old kid to build them a bumper, they probably wouldn't feel too great about it. If these things turn out nice, hell yes I'll do more for anybody that wants one, though.

[sl3807]

kyle, if you have access to a program like solidworks or catia I have a few bumper designs exactly like that done up already because thats the design Ive wanted to go with for a while, I just dont have any $$ for scrap steel until a few other projects are done. Id love to help with it but dont have any of the tools you might need. let me know if you do want some extra hands or some designs.

I have both CATIA and Solidworks at home, and could be of assistance in this area. Let me now how I can help. I have been tossing around the idea of deisgning a set of bumpers for my truck as well.

[Quick Draw]

So I took my hitch and rear bumper off....it is looking SOOO badass, with some more clearance in the rear. And the weight off of my poor soft rear springs really boosted it up too. I almost want to chop the bedsides tonight.... but nahh....maybe soon. Nate and Jay, what are you doing tomorrow? Wanna chop some bedsides? Haha...

[Quick Draw]

Jay, if you happen to see this:

Nate and I have a tentative plan to chop the bedsides Monday, after 5...

And not just Jay, anybody can come, if they wish.

[00regcab]

keep in mind, this will only be a clearance cut project, should go quick and easy (it'll be done in less than an hour). Kyle, how do you plan to set it up? What all do you want cut off? Can you get 2 pics up of your truck.

A side pic of the bed, with a line where you want it cut.
And a rear shot with a line where you want it cut, i want to get an idea as to how much you want off and such.

Nate is officially done bed bobbing after I get the body work on Russell's bed/cab done, from here on out I'll stand by, and give directions, maybe a helping hand here and there lol.

[Avsfreak1234]

Im working monday 2-close which at this point is an undetermined hour. this weekend is pretty hectic for me. but if you guys can push it to tuesday @ 6ish I could make that for sure. or thursday...but im home alone then, yall could come up and party

[Well-Strung]

If anyone needs pics of rear bumpers I have a folder or two with about 200+pics :rolleyes:

[Quick Draw]

Im working monday 2-close which at this point is an undetermined hour. this weekend is pretty hectic for me. but if you guys can push it to tuesday @ 6ish I could make that for sure. or thursday...but im home alone then, yall could come up and party

Pull your rear bumper. Then we can maybe reschedule, and do 2 at once...

And Thursday is my very last day of school....I could justify some celebration....haha

[00regcab]

No mid-week party for me... im unfortunately stuck working monday-friday 8-5.

We could do it tuesday around 6:30 if you'd be able to get your rear bumper removed jay, and if kyle would still be available then?

[Quick Draw]

I could do Tuesday.... I was actually going to head up to Kelly Flats (bumperless :eek:) on Monday, so that gives me less of a time crunch.

[Avsfreak1234]

so tuesday kyles place 6:30? I can try to get the bumper off before then. pm me directions so I can get there bro. :D

[Quick Draw]

PM sent. Anybody else that wants to drop by is welcome to also. Let me know. You can also call me at 303-941-0530

[Quick Draw]

I'm at it again....with a ton of new dents in the bed and tailgate, with the lack of a rear bumper for about a month now....

I finally started fabbing up some mounts. I cut apart the hitch that has about a 4" drop to it. I cut the frame mounting portion off, flipped it over, and welded it back on, to make it a rise rather than a drop. Then, I removed the massive gusset, ground the 1/4" plate down smooth, and cut a 2"x4" "cradle", if you will....for the square tubing. A trip to the hardware store, and I can set 2x4 square tubing on the rear of my truck, right where I want it. I'm fine tuning the placement using oval holes for the depth, and washers for the height. As soon as that's set, I will have a mounting system, and can get started making the actual bumper. Pics coming very soon.

[00regcab]

sweet, congrats

i just finished up my bumper last night!

did all of the body work/prep work today after work (just got home)

and im going in at about 6:30 tomorrow morning to paint my bed/bumper :cool:

[mrdoug]

Right on man.. but hell, I'm sittin here trying to picture what you're doing and came up with something that looks like a wing on the back of a ricer (no offense Nate).

:worthless:

[Avsfreak1234]

damnit kyle, I need to get on mine too but havent had any time or the steel yet or a welder. im just sol this time of year.

[00regcab]

Right on man.. but hell, I'm sittin here trying to picture what you're doing and came up with something that looks like a wing on the back of a ricer (no offense Nate).

:worthless:

its ok doug

my civic retains all of its FACTORY OEM spec body panels, and it'll forever stay that way :cool:

prime example ;)
http://users.4x4wh.com/4x4master/Hondar/1-26-08/8.jpg

I'll have pics of my truck tomorrow :)

[Quick Draw]

Ok, here's the pics:

Here you can see the hitch cut apart. From left to right: Lopped off side, 1 finished mount, and remenants of the hitch, that I will have to cut apart later
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2015.jpg

Close up of the final product:
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2016.jpg

How they work:
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2018.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2019.jpg

Here it is tacked up on the truck:
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2021.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2022.jpg

I tacked up the the license plate real quick, just because I had to run an errand, and didn't feel like getting pulled over....I'll cut it off and do it right later...

And my dog, just because he was standing there during the photoshoot....
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2024.jpg

[ike]

Looks great.

[mrdoug]

Ah, now it makes sense. Great work. I like the creative use of the old hitch.

BTW Nate, that's the exact color of orange I was talking about. Would love to have my 85 painted that color some day... you know.. when it actually runs.

[Quick Draw]

Have the actual bumper built! :woot:

Now I just need to build my secondary mounts for the sides...weld on D-rings, a receiver, a license plate mount, and contemplating a hi-lift mount. After that, primer and paint, then bolt it back on! It's turning out GREAT

[Quick Draw]

Here's what I got done today:
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2026.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2027.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2028.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2029.jpg

I have some more grinding to do to make it look the way I want....but that's pretty much the shape it will be.

[Quick Draw]

Here it is on the truck:
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2030.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2031.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2032.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2033.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2034.jpg

[Avsfreak1234]

damn that looks good kyle! im gettin my steel monday and should be able to make some measurements and cuts during the week but im still without a welder. I think I can get everything cut to my satisfaction and weld it all together at a later time (asap)

btw, has your tailgate always been smashed in at the bottom?

[Quick Draw]

btw, has your tailgate always been smashed in at the bottom?

Lol....no....did that on carnage a few weeks ago.... Wouldn't have happened with a rear bumper...:rolleyes:

[00regcab]

watch it, your bed moves A LOT, mines spaced quite a bit more then that and every once in awhile i still hear it smack my bumper. Also, with your bumper that close to the bed, the tailgate is going to rub when you open it.


Looks good though

[Quick Draw]

watch it, your bed moves A LOT, mines spaced quite a bit more then that and every once in awhile i still hear it smack my bumper. Also, with your bumper that close to the bed, the tailgate is going to rub when you open it.


Looks good though

Thanks for the tip. I'll keep that in mind. Fortunately, I can still space it downward if I need...

[Asha'man]

Do we have the next Armorology on our hands? ;) Looks good! As Nate said, I would allow a bit more room for bed flex, but it looks great the way it sits.

[mrdoug]

watch it, your bed moves A LOT, mines spaced quite a bit more then that and every once in awhile i still hear it smack my bumper. Also, with your bumper that close to the bed, the tailgate is going to rub when you open it.


Looks good though

?? My bentup bumper sits damn close to my bed with _just_ enough room to let the tailgate swing down. I haven't had many issues with the bed moving, but I have had my bumper slip in it's mounts slightly and make contact after some really hard hits.

I don't think you have a body lift (tho kyle does), could that be contributing to your bed movement?

[jarboarder1]

looks good man. Im planning on making something cheap similar to yours.

Looks like your tailgait could have used it earlier. Mine looks the same:lmao:

[Quick Draw]

Well....I put in a lot of work today, and I've got a good sturdy bumper now:

http://i22.photobucket.com/albums/b302/fretslider51/DSCN2040.jpg
A little more spaced down...
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2039.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2039.jpg
A rather unattractive underside view:
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2051.jpg
It passes the hi-lift test! ...I just need a bigger hi-lift....
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2048.jpg
And some urban wheeling to celebrate:
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2049.jpg
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2053.jpg

[Quick Draw]

Basically, now I just need to get some rubber stripping stuff on the bottom side of the sheetmetal, weld in a reciever, d-rings, the prime and paint. Its getting there, and I'm really pleased so far. I'll get some pics in the daylight....My truck always looks terrible under the flash of a camera...it really highlights rust and such.

For those intrerested, I nearly rolled the truck about 2 minutes after those pics....If I got a picture of the massive wheelstand that I did, it would have blown your mind....but I was too damn scared to move....so I just drove out of it. I'll go tell about it in the General Discussion Section....

[hurley842002]

very nice, thats along the same lines of the design i'll be building, except mine will stick out a bit further in the back to accomodate a tire carrier, but good work.

[ike]

looks like it tweaked under the high lift, but it could just me my eyes messing with me.

[ducaria]

The way I was thinking was using channel iron for the back but im contemplating between bolt on or welded. Why did you go bolt on?

[RedRunnertc]

looks like it tweaked under the high lift, but it could just me my eyes messing with me.

x2

Love the way you curved the front to match the wheelwells though!

[Quick Draw]

I see what you're saying... Checked that out a little deeper, and I didn't have the bolts as tight as they really should be. Also, my side mounts aren't completely finish welded yet, so they flex just a tad. Finish welding them would have required removing and putting the bumper back on twice in one night, and once was more than enough.... Trying to lift that akward thing up 3 feet and slide bolts into place all alone is a bitch! Anyway, tighter bolts and finish welds should stiffen it up!

[00regcab]

?? My bentup bumper sits damn close to my bed with _just_ enough room to let the tailgate swing down. I haven't had many issues with the bed moving, but I have had my bumper slip in it's mounts slightly and make contact after some really hard hits.

I don't think you have a body lift (tho kyle does), could that be contributing to your bed movement?

mine doesnt move front/back, but it bounces. Glance in your mirror on a washboard filled road, and you'll notice how the bed is moving differently from the cab.

All of our trucks do it since both the bed/body sit on rubber mounts. In a few of my videos, you can see me slam my bumper into a rock, then my cab/bed shake differently from the rest of the truck.

Its not much (very very slight, MAYBE 1/4" at most), but its gets extremely annoying with that clearance isnt there and you hear it rattling/tapping the body.

In this picture here, you can kind of see what im talking about:
http://i22.photobucket.com/albums/b302/fretslider51/DSCN2048.jpg