my first real project

well a few months ago me and a buddy went halfs on a powerultra 205. did some minor stuff like build ramps for a trailer and made some cuts here and there and so far this thing is awesome. so i finally decided to start making my bumpers for my jeep. i'm using some 3/16" to try and keep the weight down.

here's what i'm working with

http://i120.photobucket.com/albums/o...y/PC310009.jpg

started with this after a few cuts

http://i120.photobucket.com/albums/o...PC270148-1.jpg

thought the face was too tall so i took an 1 1/4" off

http://i120.photobucket.com/albums/o...y/PC270150.jpg

got a little farther today

http://i120.photobucket.com/albums/o...y/PC310007.jpg

couple other views

http://i120.photobucket.com/albums/o...y/PC310008.jpg

http://i120.photobucket.com/albums/o...y/PC310005.jpg

http://i120.photobucket.com/albums/o...y/PC310006.jpg


so far the bumper weighs less then a 100 lbs. i have a couple other pieces to cut and some bracing to put in along with a couple d ring to make out of 3/4" but it looks like i'm gonna make my goal of the completed bumper weighing in at less then 150 lbs. now i gotta decide if i'm gonna paint it out powder coat it

Looks good. Are you going to make a matching rear bumper too?
Wayne

Powered coat would be the way to go if you have access to an oven that will handle that monster.

Looks nice. Did you mock it up first, or just went for it. Looks very straight and clean.

Look,s good so far.
If i where you i would use 1/4" plate for the Winch mount plate in case you want to add one in the future and also drill your holes for accepting the winch foot mounts before welding everything in place. And of course cut out the fairlead opening.
If you plan on doing this just let me know and i can give you all the dimensions / measurements for this.
Cheers

Smart thinking Duncan.

no mock up i saw a bumper i liked and stole their design and modified it to suite my needs and basically cut and tacked everything into place as i go. when i'm done with this i'm gonna make a rear bumper similiar to custom 4x4 fabrications bumper but make it stick out enough to be able to use it as a step to get on top of the jeep.

i'm eventually gonna put a winch on it but haven't decided what brand yet. mostly likely will go with a smittybilt since i know some folks at 4 wheel parts who can hook me up. so you don't think the 3/16" will work for a winch mount? i don't have any 1/4" laying around and i'm currently working so much that getting to a steel yard is next to impossible. i've had this sheet of 3/16" for almost 2 years as you can see from the rust. i also need to figure out a removable rod rack to mount on the front for beach fishing.

if i can find somebody close by who can do the powder coating that's what i'll do if not i guess i'll have to paint it.

i need to get a argon bottle so when i'm done mocking it up and i can put some clean pretty welds on instead of the god aweful welds i do with a stick. i ended up selling my half of the welder to the guy i bought it with and when i get my tax refund this year i'm gonna get a powermaster 256 so i can do aluminium. i can't belive how nice these little welders are for the price you pay. i also tried cutting a piece of 3/4" plate i had laying around and was suprised how well it did considering the tip was all blown out at the time. btw what would be the best setting for cutting some 3/4"? i turned the heat all the way up but didn't know how high i should turn the compressor.

Shawn,

I cut some 3/4" yesterday with a power plasma 50. I would go 50 amps and 70PSI.

For a better looking weld use some 7018 AC rods and weld in AC.
Wayne

Shawn, It's fun to see what we can come up with when we go for it.
It seams like there are so many after market parts out there.But the way I
look at it, I tell my son if we didn't make it we sure dont want to use it.Keep up the good work.

A 1/4" plate is normally the recommended thickness for a Winch but if you are looking at the Smittybilt 8k then 3/16" should be OK you can reinforce the rear section by welding a lip to add strength so you get no flex over the length. Keep in mind the smittybilt is approx 21-1/4 length with a 10 x 4.5 pattern. If you opt for the 8k then i would replace the Detent screw for the ball bearing on the handle immediately. This is a throw back to the T.Max design and it never worked properly from the start.
The Guy that designed this Clutch release is a pretty smart Cookie but he refuses to admit that he screwed up on this detail. I have had a few arguments over some of his newer designs this past year and it is difficult to get him to admit some of his ideas are not the best for the long run.

The biggest joke is his Mounting on his Truck for a Winch. I have never seen such a pile of **** as this so called winch mount. I would be afraid of it falling off just driving down the road.
I have a feeling that Smiitybilt Winches may not be using the manufacturer from last year too much longer as they are looking for a cheaper manufacturer. They where supposed to have my Hangover winch ( i swear i was still drunk when i started this idea for the Compressor Winch ) in the 10k model this year in fact they have advertised it all year but are still to get it.
OK this thread is to long . It is supposed to be a welding thread not Winches
Sorry

i was actually looking at the 10k or the xrc 10k. i'm also adding alot of bracing to the inside. once i get the bracing in i'll post up some more pictures since i've been a bit too busy lately to make any progress

well i finally got around to finishing the front bumper here's a couple pictures just before i start painting it...which will be in about 10 minutes

http://i120.photobucket.com/albums/o...storey/001.jpg

http://i120.photobucket.com/albums/o...storey/002.jpg

got a mig 200 with my tax return and put it through the passes welding this thing up and i must say i love this little welder. i've used a couple lincolns and a miller 200 and i think this everlast unit is better then all 3 of the name brand units i've used. put it this way i absolutely suck at welding thin stuff but with this unit and all the control you have on it i was able to weld up the exhaust for my jeep without burning a single hole in the pipe. i've never done that with a name brand units on the lowest setting possible.

now as soon as the new plasma's come in i'm gonna order me 1 of them and maybe even a 225lx tig

shameless plug for some consumables hopefully

http://i120.photobucket.com/albums/o...orey/001-1.jpg

and yes i'm in the process of building a cart i even have most of the steel for it but i blew the headgaskets on my truck so i needed the jeep done so i have something to drive until i can fix my truck

If you think suck at welding steel, you best have a grinder. Make sure the penetration is good. Also by the looks, I would stiffen it with brackets inside.

The bumper looks good by me from the outside. Put it on and bang it into things (small trees). See if it twists.

I would also mount the hitch to the chassis. I have hitches on the front and rear of all my toys. The front side is lighter but the rear you want to handle the weight.

All in all, looks good to me.

The bumper looks good, the finished result is appealing.

A word of caution. You need to give your welders a little more breathing room at the back. The look awfully close to the wall and a lot of stuff around them. This can restrict cooling.

the welders are actually about 2 feet from the wall and and there isn't much around the backside it just looks like it. got the bumper on the jeep this morning i'll take a picture later

An old road I took to work was nicknamed “Dead Cow Road”. I almost needed a bumper like that a few times.

So how did the finished product turn out?

What are tabs on top for, too small for tow hooks or d rings.

lol, i love seeing dead threads brought back from the grave