- Dec 4, 2011
- 568
Here we go... picture-heavy update, but there's a lot to show today! To begin with, I mentioned the receiver was rubbing on the frame cross-pipe. I made use of a 2" solid rod, a stack of boards, and a floor jack, and by bouncing on the front of the truck, I managed to get enough force to bend the bumper around the receiver and get about 1/4" of clearance. By the time I got the spacer plates welded in, I still had over 1/8" of clearance, so now the bumper slides on and off the truck smooth as you could want!
The underside bevels have all been formed and welded in place. Those outside corners were the worst to form, because not only did I have to put a curve in them, but then I had to mount them in the vice and give each piece a 45-degree twist by hand. My back is feeling it, but I got both pieces to line up perfectly with everything else before they were welded into place.
Here is the recess for the skid plate (the bevel on the far side still needs to be cut down level with the rest of the plate). Once I start making that plate, I'll drill holes across for the bolts to go through. I think this steel is thick enough that I'm going to use counter-sunk screws so there's nothing on the front profile that can snag or drag.
After using it a few times, I wasn't too happy with having the hitch-pin handle back underneath the bumper, and even without grease, it slides without hardly any effort. So after much careful calculation, I drilled a slot through the underside bevel and tapped a 5/16 hole in the end of the 5/8 hitch-pin bar. What you see here is with the pin pulled all the way out. When its pushed in place to lock a hitch, there will be less than 1" of the bar still showing. I'm going to drill a hole in the end of the bar and weld in a steel ring, which will be used to move the bar back and forth. While it is something that could get snagged, this setup should make the hitch-pin very easy to use, and if this piece does get mangled, I can just unscrew it and replace it with another 5/16 rod.
Since I still need to pick up a new grinding disc, I haven't cleaned up the welds yet. But here's the first view of the nearly-completed bumper in place...
One thing I immediately noticed after I had the bumper sitting on the truck is the wavy profile of the bottom edge of that bevel. However it doesn't take much to straighten it up. In the following shot, I drew an angle back towards the wheel, taking off about 3/4" at the back end, but really making a big difference in how the final profile will look. And the final clearance at the back end still leaves over half the front of the tire exposed. I like it!!! (And yes, the angle of the back end of the bevel piece will also be cut tomorrow to match the top piece of the bumper.)
Looking up underneath, most of the step piece in the plastic wheel-well that was used to mount the plastic to the original bumper is still inside the new bumper. So I plan on just running a bar across the inside, and using something like the original plastic push-pins to hold the wheel-well to the new bumper. By the time I finish up tomorrow, all of the structure of the bumper will be complete.
The underside bevels have all been formed and welded in place. Those outside corners were the worst to form, because not only did I have to put a curve in them, but then I had to mount them in the vice and give each piece a 45-degree twist by hand. My back is feeling it, but I got both pieces to line up perfectly with everything else before they were welded into place.
Here is the recess for the skid plate (the bevel on the far side still needs to be cut down level with the rest of the plate). Once I start making that plate, I'll drill holes across for the bolts to go through. I think this steel is thick enough that I'm going to use counter-sunk screws so there's nothing on the front profile that can snag or drag.
After using it a few times, I wasn't too happy with having the hitch-pin handle back underneath the bumper, and even without grease, it slides without hardly any effort. So after much careful calculation, I drilled a slot through the underside bevel and tapped a 5/16 hole in the end of the 5/8 hitch-pin bar. What you see here is with the pin pulled all the way out. When its pushed in place to lock a hitch, there will be less than 1" of the bar still showing. I'm going to drill a hole in the end of the bar and weld in a steel ring, which will be used to move the bar back and forth. While it is something that could get snagged, this setup should make the hitch-pin very easy to use, and if this piece does get mangled, I can just unscrew it and replace it with another 5/16 rod.
Since I still need to pick up a new grinding disc, I haven't cleaned up the welds yet. But here's the first view of the nearly-completed bumper in place...
One thing I immediately noticed after I had the bumper sitting on the truck is the wavy profile of the bottom edge of that bevel. However it doesn't take much to straighten it up. In the following shot, I drew an angle back towards the wheel, taking off about 3/4" at the back end, but really making a big difference in how the final profile will look. And the final clearance at the back end still leaves over half the front of the tire exposed. I like it!!! (And yes, the angle of the back end of the bevel piece will also be cut tomorrow to match the top piece of the bumper.)
Looking up underneath, most of the step piece in the plastic wheel-well that was used to mount the plastic to the original bumper is still inside the new bumper. So I plan on just running a bar across the inside, and using something like the original plastic push-pins to hold the wheel-well to the new bumper. By the time I finish up tomorrow, all of the structure of the bumper will be complete.