prerunner bumper build

Discussion in 'Chevy Truck Accessories' started by reggiecab2000, Apr 16, 2013.

  1. reggiecab2000

    reggiecab2000 Epic Member 5+ Years 1000 Posts

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


    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.

    IMG_2509 (640x480).jpg

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

    here was my first two bends...

    IMG_2520 (640x480).jpg

    second two bends...

    IMG_2521 (640x480).jpg

    my brother is holding it up for a visual reference

    IMG_2522 (640x480).jpg

    once again visual reference

    IMG_2523 (640x480).jpg

    now to begin my point of no return...

    starting with sawing off the frame horns...

    IMG_2525 (640x480).jpg

    IMG_2526 (640x480).jpg

    here was after my first cut

    IMG_2527 (640x480).jpg

    IMG_2528 (640x480).jpg

    looking good so far after second (what was supposed to be final cut)
    IMG_2538 (640x480).jpg

    then I noticed this...
    IMG_2539 (640x480).jpg

    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.

    IMG_2547 (640x480).jpg

    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
  2. ahmitchell1

    ahmitchell1 Rockstar 4 Years ROTM Winner 1000 Posts

    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
  3. reggiecab2000

    reggiecab2000 Epic Member 5+ Years 1000 Posts

    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.
  4. ahmitchell1

    ahmitchell1 Rockstar 4 Years ROTM Winner 1000 Posts

    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
  5. redNecKansas

    redNecKansas New Member

    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.
  6. SurrealOne

    SurrealOne Former Member ROTM Winner 1000 Posts

    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.)
  7. aloxdaddy99

    aloxdaddy99 Epic Member 5+ Years 1000 Posts

    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!!!!
  8. reggiecab2000

    reggiecab2000 Epic Member 5+ Years 1000 Posts

    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...

    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 :)
  9. SurrealOne

    SurrealOne Former Member ROTM Winner 1000 Posts

    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.
  10. reggiecab2000

    reggiecab2000 Epic Member 5+ Years 1000 Posts

    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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