How to make a bumper for your buggy.(56k warning)

[TcmaBoy]

So, I figure I will start one.
Baby got a new bumper. At long last I have finally found the time to build a front bumper thingey for my little truck.
Before:

After:

My bumper foundation is a piece of 3x2 .120 rectangle tube. I notched it to fit down over the frame rails so that the weight would be carried on top of the frame rather than by the end caps. It also places two contact surfaces 90 deg apart so that it will resist the tendency to twist up.

I used an upper hoop made from 1.5 .120 DOM.

I made some ears to hold the hoop to my existing cage from some 1/4 inch cold rolled plate. I have 2 7/16 grade 8 bolts on each side to secure the hoop to the tabs.

Here is something you don't want to forget. I put a spacer between the plates to prevent them from warping shut during welding. I didn't think of it on the first round of welding and it was a pain to spread them back out.

Using a DOM scrap, a pry bar as a wedge, a torch, and BFH I managed to get this one opened back up. The heat from the next round of welding helped it retain its shape.

The hoop drops in rather nice.

To figure the angle and length for the uprights I made a jig and measured the distances. A little trig later and I had the sizes and angles for the uprights. Who would have thought math would come in handy in real life.

The uprights are 1.5 .120 square tube. Notching it out for the DOM was real fun. I used a chop saw to make a series of slices to take out the bulk material and then used a grinder to clean them up. I used a piece of scrap as a reference. I actually got a half way decent fit.

So, is it strong? Yep, I used the high lift to pick up the front end. Even without the bolts in the hoop it managed to take the full weight of the front end. I only went high enough to barely lift the front tires because the high lift got a little tippy.

The nice part of this design is that it is removable. I can unbolt it and remove it to get to the motor.

Now I just need to go find something to test my pretty new bumper thingey. Anyone have a Honda they can spare?

[Brian R.]

Nice strong design

[Brian R.]

I just have one question...

Where's your radiator???

[Flash75]

I was thinking of asking the same question. I think there may be two coolant hoses running toward the rear.

Clifton

[TcmaBoy]