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Discussion Starter #1
Well I want to sell the ARB, and I have a buyer lined up, but the more I think about what I'm going to be replacing it with. The more I shy away from selling it.

I've looked around at different bumper designs, and I personally do not have the fab skills myself to build something that would be aesthetically pleasing enough to meet my standards. Where as, I also do not have pockets deep enough to fork out the $$$$ for an Armology or something similar to it.

I've played around with a few different designs/ideas in a 3d program I have, and while they all look decent in a program, not too sure how they'd look on a truck in person.

I want to go with a plate style bumper, but I do not have the tools, or the knowledge to even go about starting a plate bumper. Heres a couple different ideas i brewed up (none are plate currently, but just some things i had saved on the comp that i changed up a little).

"Evil-eye" tube bumper:


Very basic square tube (obviously, reality would bring more bracing, and such)


Another design I like a lot, is the bent up, however I don't have the need/want for a winch so I would go custom with it and make it a more 'shallow' bumper that didn't stick out as far without a winch plate behind it. I want to keep the bumper tucked up as high, and as close to the truck as possible for better approach, and leave the area in front of each tire more open.

So what it boils down to, I'm looking for some opinions from those of you who have fabbed your own bumpers as to what i should look into, and if i could get some help from one of you to do this. If i cant come up with a good idea in the next few days, I'll have to hold off on the ARB for now. So that's what is kind of pushing me through it.
 

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The thing about round is you need a bender and the right dies ... plate or rectangular, the tools are a lot easier/cheaper.

If you wanted to contribute some funds to wire, gas, and a chop saw, I would love to help you out with it.
 

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The carrot has been dangled :D I like the idea of us trying to do it with ya!
 

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Discussion Starter #4
Kyle, (ksp1043 i think is his username?) offered up his bender for me to use in the making of a front bumper. He only has 1.75" die, but i had planned on doing some sort of bar across the top of the bumper (kind of similar to the arb). And i also need to do bedside protection, so it would be worth the drive to Castle Rock for me to have him help me with the finishing touches (tube work).

I'd be happy to help contribute, Troy. The biggest thing is the budget. I really want to try to keep the materials around/under $200. If i can, i can swing a new clutch for my truck with the rest of the money out of my arb. If not, its not going to be a huge ordeal, but its my goal for the project.

Do you think its something we could knock out in a day, or would you rather do a weekend, or a day here, day there, type ordeal?

Really want some input from both Isaac and Ike on this subject, as they've both done 'plate' bumpers that turned out really well. Ike's had a square tube base, but from what i remember, Isaac's was 100% plate.
 

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I think doing it in a day would be pushing it - especially with how anal you are about how stuff looks!

Probably first day would be figure out the mounting, get everything cut, mocked in and tacked. Next day would be finish weld and grind.

Let me know several days in advance and I'll try to borrow the plasma cutter.
 

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$200 is really freakin' pushing it... but I know you get good deals on steel...so maybe you can do it. 100% plate wouldn't be do bad to fab up, however tubing will be a lot lighter for the same strength. If it was me building a front bumper (and I will be soon) I would probably do a design similar to your 2nd rendering, but with more corners than curves, because that's a mother fucker to do, unless you like grinding...as you know.
 

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Discussion Starter #7
Thats very reasonable, and understandable, Troy.

It doesn't have to be done in 1 day by any means, was just curious as to what plan of attack you would like to take.

So would you prefer setting aside a whole weekend (sat/sun) or do back to back weekends (one of the days, two weekends in a row) ? Whichever will work better for you. I still need to price steel and what not, which is another thing i should of put in my first post.

What would be best? The bumper will get used pretty hard I'm sure, but i want to try to keep it a little bit lighter than the ARB is. I was thinking a mix of 2x3 .188 wall, 2x2 .188 wall, 2x2 .120 wall, then some moderately thick plate steel (not sure on thickness for this one). Would it be too much to go with these thicknesses?

Thinking of the .188 wall for the main cross bar/wrap around, and the supports/new cross member in the frame.
 

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Discussion Starter #8
$200 is really freakin' pushing it... but I know you get good deals on steel...so maybe you can do it. 100% plate wouldn't be do bad to fab up, however tubing will be a lot lighter for the same strength. If it was me building a front bumper (and I will be soon) I would probably do a design similar to your 2nd rendering, but with more corners than curves, because that's a mother fucker to do, unless you like grinding...as you know.
hah, yea.... my rear bumper :eek: It was worth every bit of the work though, with the finished product.

It was a rendering, and it was just easier to make it slightly curve than block it out like it would be in reality. I wouldnt be looking for a nice smooth rounded finish like that, but not something excessively blocky/pointy either.

Completely understand what you're saying with that though.

Good deals on steel is a huge plus, my moms good for quite a few things apparently :lmao:
 

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About what thikness i used on mine, and mine is actually very light. I can easily manage it. It hasn't been on a scale, but my guess would be only about 50 lbs.
 

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Well, the ARB is ALL plate, no tube and either .120 or .188 ... not quite sure how you're gonna get away with much less material if you're using tubing ... I would do .120" for everything except the mounts, where I would be thinking .25"
 

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:xpopcorn:

Been wanting to build one for my 07 for some time now. I also don't have the cash to have a shop do it. Let me know hit it works out since I plan on building a plate bumper sometime in the next year. (It sucks not having any fabrication skills)
 

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Discussion Starter #14
Troy said he had a chop saw.

So, Troy. You're saying i should use .25 for the mounting (new front x-member, and the main legs of the bumper)?

I plan to do something like Ike did. Build the base out of square tube, then plate over that to have a more "finished" look to it.
 

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I did my front crossmember out of 10 gauge. slightly thicker than the frame. Just didnt feel comfortable making the bumper mounting that much stronger than the frame. Mine wraps around all 4 sides and the front of the frame horns then. I think it is plent strong, but i wont know for sure until it gets used.

Also all of my material cost about 100 bucks, so you should be able to make your budget as long as you plan ahead. I made the cross member, then bought what was needed for the frame of the bumper, and then for the finish pieces. Mine didnt turn out as good as i want it to be, but i am only out alittle cash, and learned a ton for the next build.
 

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They just come with practice. Become freinds with someone with a welder, buy some metal, cut off wheels, grinding wheels. Throw the person some beer and cash for welding supplies and start learning.
 

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I was thinking of the rear, where you are bolting to the side of the frame ... yeah, with the crossmember stuff in the front, you don't need to be that heavy.

I would HIGHLY recommend you have a hitch receiver in the front.
 

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I wish i would have planned better for one. If i were to do it again i would make my cross member out of 2x4 instead of 2x3. Then i would cut a hitch reciever into it in the center. Will make makeing the sleves a little more difficult, but you will have a solid easy way to mount the reciever. I would also but a decent size scab plate on both sides of where the hitch reciever gets cut in. Puts it low where it stresses the frame the least. Downside is it cuts into aproach angle, but not by much and only a 2 inch wide section in the very middle of the bumper.
 
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