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Discussion Starter #1
When I bought my truck this summer it had no rear bumper on it. After further examination I found that to be for a good reason. The truck had been rear ended by someone which bend the rear section of the frame down, and the last 2 bolts holing the bed to the frame were missing. It was enough of a bend that a bumper would not bolt up. Since I am down in Texas for the holidays, I wanted something to do so I decided to fix the frame and build a beefy rear bumper! This thread will be updated as I progress!

I used 4" C channel to fab all of this since it was available at my uncles shop and it fit perfectly around the frame!

You can see by the first pic how bent the rear of the frame is...


Here is a pic of one side torched off behind the shackle mount.


That is the pieces I had to cut and fab to make the frame the same length as before. This will allow me to move my shackle mounts when I do my Chevy leaf spring conversion, and will be A LOT stronger than the stock one.











Here are both sides welded up.



Here is the rear crossmember I welded in for some added support.



Arc welding upside down is no fun at all!











More to come as I get more time to work on the bumper! My design is kindof like the warn rear bumpers but mine will wrap around the sides and be supported to the frame, and have a small tube hoop up the side.
 

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Discussion Starter #3
Thanks! Bottom welds don't look amazing, but I didnt get around to grinding them, but they are strong!
 

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you have enough weld lenght on the other sides that it should be more than strong enough.
 

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Actually, it doesn't appear there is much weld surface at all between the new section and the old - or am I missing something?

Looks to me that there is just the one weld around the end. In a dynamic recovery, I would want more than that. Can you put a couple grade 8 bolts through it, so you would have the shear force to help?
 

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Discussion Starter #6
The outside piece of C channel is welded to the frame on the inside and outside in every place possible to weld. It is very strong! The inside piece was mainly welded to the first piece of channel , seaming them together, but beads were ran lengthwise on the inside of the box as well as the outside. There were a few spots where the inside piece was welded to the actualy frame.I will be putting grade 8 bolts through for the bumper. I should have shown more pictures of all the welds that were used to hold them on, but it is solid!
 

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The outside piece of C channel is welded to the frame on the inside and outside in every place possible to weld.
Ahh - OK. That's how I would have done it too!
 

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only real way to get more weld would have been to drill holes in the side of the frame extension and then weld to the frame by those holes as well.
 

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Discussion Starter #10
only real way to get more weld would have been to drill holes in the side of the frame extension and then weld to the frame by those holes as well.
And I did debate that! I waited till I got everything else welded to see how sturdy it was and decided I didnt need them. I wanted something strong enough to attach a bumper to AND support the new shackle mounts I will be putting on later down the road.
 

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Discussion Starter #11
Did a little bit of work on the bumper tonight... I forgot my camera, so pics will come hopefully tomorrow. I got my design idea from one of my offroading magazines. I am building a "shell" or skeleton out of 3/16 steel rod. This will give me something to trace my panels onto a sheet of plate steel I have, and be able to build more bumpers off of my skeleton bumper. So far it is looking pretty sweet!
 

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Discussion Starter #12
Did some more work on the bumper "skeleton" today and here are the pics. I have the skeleton completely done now just have to trace each plane onto the plate steel and cut them out! This template also allows me to make more of these bumpers in case anyone on here likes them and wants one.









 

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That skeleton is looking good! If this were my project I would just cut the bed sides and have that wrap around piece go underneath the bed instead of wrapping around the outside of it. But this just my personal preference.

Can't wait to see the finished project!
 

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Discussion Starter #14
Thanks! It will be attached under the side of the bed also. Those side pieces will have a tubular hoop going up to help protect the sides of the bed also.
 

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Discussion Starter #16
In the picture of me holding the skeleton, you can see I did add in some bracing. It is 3" thick to add some bracing. I am also going to add triangular gussetts when I build the actual bumper.
 

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Is that skeleton going to make its way into the finished product or is it purely for mockup purposes? Neat idea either way.
 

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Discussion Starter #19
I used the skeleton to trace each "plane" of the bumper onto a sheet of plate steel. I have all the pieces traced out and cut, and am working on assembly of it now! I need to upload the pictures of it!
 

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Discussion Starter #20
Got some more done the other night... I have everything cut out and all the edges cleaned up. I have 6 pieces welded together right now and should have it all done tonight! Here are pics of everything except what I did today.




 
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