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  1. #1

    Default prerunner bumper build

    Alright guys Im gonna go ahead and start this thread for my bumper build and update it as progress continues...

    materials:

    1) JD2 pipe bender
    2) 1.5" schedule 40 pipe
    3) level
    4) tape measure
    5) welder
    6) drill press

    Heres what I got started last weekend...

    had to mount our new JD2 pipe bender, since I knew we had no place other than dead center of our guest house garage, I knew it would also have to be movable, so I used female concrete anchors, so I could store it out of the way when not using it.

    Click image for larger version. 

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    setup done, now time for lots of measuring and tedious thinking...

    here was my first two bends...

    Click image for larger version. 

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    second two bends...

    Click image for larger version. 

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    my brother is holding it up for a visual reference

    Click image for larger version. 

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    once again visual reference

    Click image for larger version. 

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ID:	51488

    now to begin my point of no return...

    starting with sawing off the frame horns...

    Click image for larger version. 

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    Click image for larger version. 

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    here was after my first cut
    (THE METAL BLADES ON THE SAWZAW CUT THROUGH LIKE BUTTER!)

    Click image for larger version. 

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    Click image for larger version. 

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    looking good so far after second (what was supposed to be final cut)
    Click image for larger version. 

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    then I noticed this...
    Click image for larger version. 

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    My truck was totaled my junior year in high school thanks to the most favorite NBS, ABS sensor defect, that GM has no motivation to ever fix. And i never thought that my left front frame horn couldve been replaced.... well apparently it was, and when it was replaced, it seem they cut about 1/2" extra off before welding the replacement horn back on, which is weird because my stock bumper sat just fine...

    its really not too much of a setback, since this is a CUSTOM bumper, but id rather everything be even on both sides just for easier measurements.

    Click image for larger version. 

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ID:	51495

    this is after I used some leftover rustoleum bed spray on the front frame to keep rust from attacking my fresh new cuts...

    thats all i got done for my first weekend...

    near future plans:

    1) make sure frame ends are even
    2) find some 1/2" sheet steel to weld into my frame horns to cap them off, and provide a solid mounting point for my bumper
    3) cap ends of main tube
    2000 Chevrolet Silverado

    Powertrain:
    4.3L V6, 4L60E, 2WD, Single Cab
    Performance:
    Airaid CAI
    Poweraid TB Spacer
    Flowmaster 10-series exhaust (dumped)
    BLACKBEAR TUNED!!!
    Edge CS insight monitor
    4.10 gears
    Limited-slip differential
    LS-1 Dual Electric fans
    Corvette tranny servo swap

    Audio:
    Head Unit: Alpine
    Speakers: Alpine SPR-60C 6.5" component set, 4X6 Infinity Kappas
    Subs: 2-12" Kicker CVT's
    Amps: Alpine-M1000 (subs), Alpine MRX-F65 (Speakers)


    Tires/Wheels:
    305/70R16 NITTO Terra Grapplers
    16" PROCOMP 7089's
    Suspension:
    2" leveling kit
    3" Fabtech Spindle Lift Kit
    Front/Rear-Bilstein 5100 shocks

    Lighting:
    FRONT
    35W HID Low Beams
    RECON LED smoked roof cab lights
    REAR
    HELLA LED taillights and 3rd brakelight
    HELLA FF-75 Aux. Reverse Lamps
    RIGID dually D2, flush mount, wide beam
    Accessories:
    Hawk HPS Brake pads
    Russell braided steel brake lines
    Powerstop-red powdercoated brake calipers
    Powerslot Cryo brake rotors
    EGR in-channel window visors

  2. Thanks mfleetwood thanked for this post
    Likes mfleetwood liked this post
  3. #2

    Default

    Quote Originally Posted by reggiecab2000 View Post
    Alright guys Im gonna go ahead and start this thread for my bumper build and update it as progress continues...

    materials:

    1) JD2 pipe bender
    2) 1.5" schedule 40 pipe
    3) level
    4) tape measure
    5) welder
    6) drill press

    Heres what I got started last weekend...

    had to mount our new JD2 pipe bender, since I knew we had no place other than dead center of our guest house garage, I knew it would also have to be movable, so I used female concrete anchors, so I could store it out of the way when not using it.

    Click image for larger version. 

Name:	IMG_2509 (640x480).jpg 
Views:	838 
Size:	44.8 KB 
ID:	51483

    setup done, now time for lots of measuring and tedious thinking...

    here was my first two bends...

    Click image for larger version. 

Name:	IMG_2520 (640x480).jpg 
Views:	740 
Size:	38.5 KB 
ID:	51485

    second two bends...

    Click image for larger version. 

Name:	IMG_2521 (640x480).jpg 
Views:	815 
Size:	37.8 KB 
ID:	51486

    my brother is holding it up for a visual reference

    Click image for larger version. 

Name:	IMG_2522 (640x480).jpg 
Views:	876 
Size:	42.2 KB 
ID:	51487

    once again visual reference

    Click image for larger version. 

Name:	IMG_2523 (640x480).jpg 
Views:	709 
Size:	35.8 KB 
ID:	51488

    now to begin my point of no return...

    starting with sawing off the frame horns...

    Click image for larger version. 

Name:	IMG_2525 (640x480).jpg 
Views:	806 
Size:	44.0 KB 
ID:	51489

    Click image for larger version. 

Name:	IMG_2526 (640x480).jpg 
Views:	692 
Size:	36.2 KB 
ID:	51490

    here was after my first cut
    (THE METAL BLADES ON THE SAWZAW CUT THROUGH LIKE BUTTER!)

    Click image for larger version. 

Name:	IMG_2527 (640x480).jpg 
Views:	737 
Size:	42.8 KB 
ID:	51491

    Click image for larger version. 

Name:	IMG_2528 (640x480).jpg 
Views:	674 
Size:	33.7 KB 
ID:	51492

    looking good so far after second (what was supposed to be final cut)
    Click image for larger version. 

Name:	IMG_2538 (640x480).jpg 
Views:	680 
Size:	44.3 KB 
ID:	51493



    then I noticed this...
    Click image for larger version. 

Name:	IMG_2539 (640x480).jpg 
Views:	751 
Size:	53.5 KB 
ID:	51494

    My truck was totaled my junior year in high school thanks to the most favorite NBS, ABS sensor defect, that GM has no motivation to ever fix. And i never thought that my left front frame horn couldve been replaced.... well apparently it was, and when it was replaced, it seem they cut about 1/2" extra off before welding the replacement horn back on, which is weird because my stock bumper sat just fine...

    its really not too much of a setback, since this is a CUSTOM bumper, but id rather everything be even on both sides just for easier measurements.

    Click image for larger version. 

Name:	IMG_2547 (640x480).jpg 
Views:	1282 
Size:	65.2 KB 
ID:	51495

    this is after I used some leftover rustoleum bed spray on the front frame to keep rust from attacking my fresh new cuts...

    thats all i got done for my first weekend...

    near future plans:

    1) make sure frame ends are even
    2) find some 1/2" sheet steel to weld into my frame horns to cap them off, and provide a solid mounting point for my bumper
    3) cap ends of main tube
    Looks like you got a good build going. You gunna be doing the welding yourself. And to bad your not in Ga I got stack of every size pipe you could imagine
    2009 chevy 1500 z71 4x4
    2.5 ccm level,2.5 inch rear blocks 305/60/18 coopers stt,Debadged,10 series flow w/dual exit in front or right rear tire, KN CAI, diablo InTune, 18% tint all the way around ,spec-d euro headlights with black housings,winjet smoke LED tail lights,putco LED third brake light smoked, fab fours front bumper with 10k warn winch, RK sports ram air hood
    1965 c10 swb, zz4 350 with the hot cam and fast burn heads and a 780 Holley on top, richmond super street 5 speed,restorod

  4. #3

    Default

    yeah I will do my best to do my own welds with friends help and my engineering shop director's guidance as well... already picked up a lincoln 180 welder from lowes, thanks to income tax! This should be the biggest project I ever use it for, it should come in handy for the rest of my life though whenever i need it.

    after i finish my bumper i will start my headache rack.
    But everything will be the same size pipe, due to bending dies being $300.00+ a piece.

  5. #4

    Default

    Yea they ain't cheap. Whenever I get around to lifting my truck I'm gunna make some step bars that look like the nfab ones but with a lot more strength

  6. #5

    Default

    I will be following your progress through this build as I am looking at doing a custom bumper build. But so far so good man looks like it will turn out pretty good.
    Jack It Up Fat Chicks Can't Jump-Kansas HickLyfe


    '03 GMC Sierra Z71 5.3- 4" Rough Country Lift Kit/33" Terra Grapplers/17" Helo Rims
    '08 Buell 1125R
    '11 Apollo Mini PitBike

  7. #6

    Default

    @reggiecab2000,
    I don't personally tend to like the prerunner look, but I have such a deep respect for the time and attention to detail required for GOOD custom fabrication (be it electrical, fiberglass, metal, etc.) that I'll be following this thread.

    Remember every bump and gotcha you run into. There always are some ... and they're what make the work fun and interesting, even if they make you curse like mad along the way. They're also what make you respond with a 'hell no!' when someone with no clue about what you went through asks you if you'll make one like yours, for them ... and how much you'd charge. LOL (But it feels good to be asked that.)

  8. #7

    Default

    What all is going to go on the bumper? Winch? Lights? Drings?
    It will be a great accomplishment to have a bad a$$ bumper on your truck that is custom built... by YOU!!!!





    2011 GMC Sierra SLE - 5.3 - 4X4 - Z71 - King Shock Level Kit - Body Color GMC grill emblem - 2 Tone Engine Cover, Rad Cover and Battery Box - Volant CAI - Tru Cool 40K tranny cooler - Sylvania ZXE bulbs Hi/Low -TriFold Hard Tonneau Cover- CoverCraft Seat Covers - Diablo inTune - GoRecon LED under rail lights - GoRecon LED White Lightning Tailgate Light Bar - Windows tinted to 45%- Kenwood DNX6990 - JL Audio C5-650 &650X- JL Audio Amp- Interco Truxus M/T 33x12.50x18

  9. #8

    Default

    thanks guys, I can tell you for now itll be at least until may before i get an update on this, due to multiple things coming up on the weekends requiring me to stay in corpus christi...


    Quote Originally Posted by aloxdaddy99 View Post
    What all is going to go on the bumper? Winch? Lights? Drings?
    It will be a great accomplishment to have a bad a$$ bumper on your truck that is custom built... by YOU!!!!
    for now the plans are to incorporate 2 to 4 lights behind the main tube, i will also be incorporating a skid plate, and depending how I brace each side of the bumper will determine the ability to enclose the side/corners with some sort of skid plate as well (to fill the emptiness commonly associated with prerunner bumpers on the sides)

    my plan is light, strong and low profile because the less weight on the front of a 2wd THE BETTER!

    and for surreal, it is a prerunner type for lack of a better term, but i am taking what i like about prerunner bumpers and transforming it into something I hope to be one of a kind, because i HATE being like everyone else

  10. #9

    Default

    It takes time. Heck, my on board air project commenced in late Q3 of last year .... and here we are in Q2 of 2013. That's 6 months. I keep wondering where it went. Thankfully I work on other projects between the fab work, as there are necessary wait periods for what I'm doing (i.e. design/fabrication I simply can't do, myself, due to the cost of tools).

    Just make slow, steady progress.

  11. #10

    Default

    well, this past weekend I was in San antonio for a couple days, and ran into my very first "snag" which ruined any progress on my build...
    Found out my welder required a different AMP rating 250V plug than either our compressor, dryer, or water heater had...
    they run on 30A, 250V connections, my welder requires a 50A, 250V connection, so needless to say i had to run to lowes to pick up a female plug, for it which is pretty cheap, but its the 8AWG wire thatll cost $1.93/foot to run through the walls and ceiling to get to the garage.... more time and money, but worth it in the end...

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