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Well - I needed a new front bumper but I just couldn't stomach paying $600 for an OEM replacement or $800+ for a steel upgrade, so I figured it couldn't hurt to try and build one myself.
Final design in CAD:
I decided on using 1/8" (3mm) A36 plate for the fascia laid over a 1x1x.125" angle frame to give it some rigidity. I don't really have the right gear to cut anything thicker, and I figured I could save some weight and cash.
However, the D-rings are functional - they're 1" thick and welded to a 1/4" (6mm) boxed cap that's bolted to the frame rails. I had one of our certified welders tackle this. The body of the bumper then slots over the d-ring brackets and is welded into place. Two additional mounting tabs then allow it to be bolted underneath each fender - I wanted to eliminate the possibility of rattles.
Frame with plates ready to weld.
It was a bit of a bear trying to get the two sides of the frame identical, but I managed to get it done. Both halves are cut from the same template.
All welded up.
I seal welded the front seams and stitched the back. Ran out of gas and had to switch to flux core wire so pardon my spatter. Also after a preliminary fit-up I saw there was a pretty big gap between the edge of the bumper and the body so I welded in some 2" bars to close it. Makes it look a lot more finished. It also feels really stout and rigid. Just a hair under 50lbs.
First fitting.
It fits well with even spacing all around. It does follow the body lines well enough. I think the proportions are a bit off and it came out too big, but I can live with it.
I still need to grind the welds, seal the backside, primer and paint, but the hard part's done. I'm finishing it off with some 4.5 ton shackles, a KC HiLites light bar and a pair of Hella 500s to make up for my removed fog lights.
In the end I spent about $150 in raw materials and another $50 or so in consumables such as welding wire and abrasive discs. I still have probably another $50 in paint and coatings to buy.
So is it doable? Yes. Would I do it again? Probably not. It's an immense amount of work getting everything cut, welded, and fit up properly. I've probably sunk at least 25 hours into it, so I can completely understand why the aftermarket guys charge so much for a bumper. But in the end I'm proud of the work and I had freedom of design which is always nice. I should be finishing it this weekend and I'll post some "after" pics - in daylight, I promise.
Final design in CAD:
I decided on using 1/8" (3mm) A36 plate for the fascia laid over a 1x1x.125" angle frame to give it some rigidity. I don't really have the right gear to cut anything thicker, and I figured I could save some weight and cash.
However, the D-rings are functional - they're 1" thick and welded to a 1/4" (6mm) boxed cap that's bolted to the frame rails. I had one of our certified welders tackle this. The body of the bumper then slots over the d-ring brackets and is welded into place. Two additional mounting tabs then allow it to be bolted underneath each fender - I wanted to eliminate the possibility of rattles.
Frame with plates ready to weld.
It was a bit of a bear trying to get the two sides of the frame identical, but I managed to get it done. Both halves are cut from the same template.
All welded up.
I seal welded the front seams and stitched the back. Ran out of gas and had to switch to flux core wire so pardon my spatter. Also after a preliminary fit-up I saw there was a pretty big gap between the edge of the bumper and the body so I welded in some 2" bars to close it. Makes it look a lot more finished. It also feels really stout and rigid. Just a hair under 50lbs.
First fitting.
It fits well with even spacing all around. It does follow the body lines well enough. I think the proportions are a bit off and it came out too big, but I can live with it.
I still need to grind the welds, seal the backside, primer and paint, but the hard part's done. I'm finishing it off with some 4.5 ton shackles, a KC HiLites light bar and a pair of Hella 500s to make up for my removed fog lights.
In the end I spent about $150 in raw materials and another $50 or so in consumables such as welding wire and abrasive discs. I still have probably another $50 in paint and coatings to buy.
So is it doable? Yes. Would I do it again? Probably not. It's an immense amount of work getting everything cut, welded, and fit up properly. I've probably sunk at least 25 hours into it, so I can completely understand why the aftermarket guys charge so much for a bumper. But in the end I'm proud of the work and I had freedom of design which is always nice. I should be finishing it this weekend and I'll post some "after" pics - in daylight, I promise.
