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prerunner bumper build

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

  1. truc.karl

    truc.karl New Member

    Looks good so far. Can't wait to see it completed.
  2. reggiecab2000

    reggiecab2000 Member


    1) bumper mounting plates made

    so summer school started earlier this week with some tough engineering classes, contrary to what I thought, I actually got some stuff done today with my shop teacher who was more than ecstatic to help me!

    heres a few hours work between my two summer classes...

    thankfully he had plenty of extra 1/2" steel laying around for me to use...

    so we popped it up in the bandsaw

    IMG_2896 (640x480).jpg

    my two pieces, yes there are already some drilled holes in them, but oh well, doesnt affect the quality of them

    IMG_2897 (480x640).jpg

    then the 4 holes for some 1/2" grade 8 bolts

    IMG_2899 (480x640).jpg

    IMG_2900 (640x480).jpg

    after cutting I test fitted and realized i needed to round the corners off

    IMG_2901 (480x640).jpg

    here they are in place to cap off my frame horns.

    IMG_2902 (640x480).jpg

    still need to tack weld the 4, 1/2" nuts on the back side of these plates, then weld these plates flush...
  3. reggiecab2000

    reggiecab2000 Member

    1) 3/8" steel for bolt on plates made
    2) nuts welded onto 1/2" mount plates
    3) mount plates welded onto end of frame horns
    4) grinded plate welds flush
    5) bolt on plate, bolted onto mount plates

    IMG_2921 (640x480).jpg
    IMG_2923 (640x480).jpg
    IMG_2924 (480x640).jpg
    IMG_2926 (640x480).jpg
    IMG_2927 (640x480).jpg
    IMG_2928 (640x480).jpg
    IMG_2929 (640x480).jpg
    IMG_2930 (640x480).jpg
    IMG_2931 (640x480).jpg

    only welded three of the sides because my shop teacher said it was already more than enough.... though it may be true, i might finish the 4th edge for aesthetics...
    IMG_2932 (640x480).jpg
    IMG_2933 (640x480).jpg
    IMG_2934 (640x480).jpg

    all that left now is to cut and weld the bumper support arms onto the 3/8" bolt on plates, and weld the bumper to the arms as well.....
  4. tbplus10

    tbplus10 Super Moderator Staff Member Platinum Contributor 1000 Posts

    I know your building this for strength and all but are you gonna design in a sacraficial crush can or anything like that so in case of an accident you crush or bend something replaceable instead of a frame horn or rail?
  5. reggiecab2000

    reggiecab2000 Member

    I dont really have any kind of crush zone in mind... BUT, I am doing this in the bolt on method as shown, rather than straight welding my bumper to the frame for a reason similar to the one you stated. Welding the bumper to my frame would mean if I was to hit something hard, and something got bent, its only logical that something on my frame would be affected. instead I opted to cap off the frame, and make a 3/8" bolt on plate which will be connected to the bumper, and I will be able to remove the bumper IF NECESSARY, but perhaps the 4 1/2" bolts would break if I was to hit something that hard, which might constitute for a crush zone you are referring to...
  6. dsfloyd

    dsfloyd New Member ROTM Winner 1000 Posts

    Looks good so far
  7. tbplus10

    tbplus10 Super Moderator Staff Member Platinum Contributor 1000 Posts

    Ok, just remember not to make the mistake of using the strongest hardware available, then you negate the crush zone (or in this case shear factor).
    Just a costly mistake I learned on an earlier prerunner bumper build.
  8. reggiecab2000

    reggiecab2000 Member

    finished my bumper!!!

    only took a few months LOL
    but here she is...

    future plans will be to incorporate a skid plate and some sheet metal for gap filling then some light mounts...

    IMG_3102 (640x480).jpg

    IMG_3104 (640x480).jpg

    IMG_3105 (640x480).jpg
  9. dsfloyd

    dsfloyd New Member ROTM Winner 1000 Posts

    good job, glad you finally got it done.

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