Swing-out tire carrier buildup!!

[Willman]

I have been working on this project for a while! For me it is hard when i work full-time and go to school full-time as well. It makes for a long day!! I have alway been wanting a rear bumper w/ a tire carrier. I got sick of my spare tire taking up the space in my bed! I shopped around and could not find anything that i liked or didn't wanted to break the bank on. A lot of fab shops want $1000 plus...and you cann't forget about the shipping cost as well...Sooo one day i got a used welder from the father-in-law and just about all a guy needs for working up a piece of art!!!!

(note disclaimer: Willman has 4 years of welding fab training. When working with metal you should have some training etc. because you could harm yourself!!!)

used Esab Migmaster welder - $200 (father-in-law deal..later found $$$ under drivers seat!!!...Free!!! I love that guy!!!!!)
Oxy/Ace torch setup - $300
Metal shop saw - Free
All the steel i needed for fab- $40
HD Hinge - $50
Toggle clamp - $80
I already had alot of stuff before - peanut grinder, misc tools etc...

So far i have spend about $500 i would say...also a few runs to the local welding shop for misc parts etc... The great thing is that i now have just about everything i need or connections to get it for future projects and mods (skid plates, roof rack w/ tent, etc..)

Here is my fab buildup:

I used a 6x3 with a wall of 3/16 for my main piece
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01073.jpg
A nice torch can be a great tool for any metal project
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01074.jpg
Now time to cap it off. This will be my air tank in the future!
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01084.jpg
Rocklogic makes a great hinge setup, http://www.rocklogic4x4.com/store/index.php?action=item&id=111
I got everything all grinded and ready to start planning my swing out arm. I cut out a piece of card board for my spare tire, thats alot lighter than the real thing!!!! I mapped out my hinge placement as well as my toggle clamp. I got the stainless steel toggle clamp from McMaster online.
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01088.jpg
I then layed out my hole for my pin for the hinge and used a 1-3/8" holesaw to make the hole
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01152.jpg
I used 2x2 w/ a wall of 3/16 as well. When i welded the hinge tube piece and with the help of OldSven we pressed in the bearing races for the hinge.(my welds sicked that day!!!!..some days your on some days your not!!..lol)
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01154.jpg
On top of the arm i am going to bend up a piece of 1-7/8" tube to hold the tire,hi-lift etc..That is coming soon! The next step was to put my reciever hitch in. I have a Warn multi-mount winch which is a great tool that is very handy!!! With the hitch, i wanted to flush mount it with the bottem of the bumper but i run into a problem with the pin placement and had to this instead..which is great too!!
Drilling hole for pin
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01156.jpg
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01158.jpg
Now to weld it up!!!
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01178.jpg
I wanted to make this hitch very strong...i put gussets round the hitch to beef it up!!!
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01179.jpg

There is alot to come!!! I will keep everyone posted as project goes on. Let me know if U have any Q's or suggestions.

-Willman-

[CLynn85]

Looks like you're off to a great start. Thanks for the link to the pre-fabbed hinge setup! I'm planning on building one this summer and that will save a bit of hassle.

[Willman]

Here is my bumper so far....I am getting ready to weld the pin in for the hinge.
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01180.jpg
I have a lots to do!!!
-Drill hole on gussets for trailer safety chains
-Bendup tube for upper arm.......and the list goes on!!!!
:smileeek:

[Desertdude]

Damn - that is talent! Nice work :Wow1:

[goodtimes]

I must throw a word of warning out there....be careful with that hinge. They have been known to fatigue, and break off while driving down the road. This is more common with the imported trailer spindles (which is what that hinge is based on...the trailer spindle...don't know if that one is imported or not). I have seen it several times in person. I used to have a similar bumper on the back of my jeep, but scrapped it because of this concern (of course, my main concern wasn't losing the spare tire going down the road, it was the 10 gallons of fuel that I had strapped on there that worried me the most).

Personally, I prefer swing outs with 2 hinges, instead of one, but the asthetics are not as nice this way.

As far as fabrication goes, it looks good! And the deal you got on your welder was much better than the one I got on my Millermatic 210.

:)

[Willman]

I must throw a word of warning out there....be careful with that hinge. They have been known to fatigue, and break off while driving down the road. This is more common with the imported trailer spindles (which is what that hinge is based on...the trailer spindle...don't know if that one is imported or not). I have seen it several times in person. I used to have a similar bumper on the back of my jeep, but scrapped it because of this concern (of course, my main concern wasn't losing the spare tire going down the road, it was the 10 gallons of fuel that I had strapped on there that worried me the most).

Personally, I prefer swing outs with 2 hinges, instead of one, but the asthetics are not as nice this way.

As far as fabrication goes, it looks good! And the deal you got on your welder was much better than the one I got on my Millermatic 210.

:)

Thanks for the great words guys!!! Do you have any pictures of that hinge..and who makes it??? The hinge i got is very beefy!! It would take A LOT to see this one fail!!! It is a pretty nice setup. You get a A+ for the Millermatic 210!!! Sweet welder!!!!:bowdown:

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/spindle.jpg
http://www.rocklogic4x4.com/store/index.php?action=item&id=111

[goodtimes]

I don't have any pictures of the hinges that failed...they were all the typical trailer spindle like you have. The bumpers, IIRC were from "smaller" fabrication shops....don't recall names, but they were not the huge mass producing places like Warn, ARB, etc. All of the failed pieces were several years old, and all had 35"+ tires on them. Just keep your eye on it for stress cracks around the top weld on the bumper...that is where they seem to fail.

The MM210 is a pretty nice welder....just wish I would have spent the extra $$$ and bought the 251 instead. About a week after I bought the 210 (figuring I would never weld anything over 3/8"...and if I did see some 1/2" stuff, I could just run 3 passes on it...), I had a piece of 1" plate come in that had cracked (part of a custom made stud press). It took 10 fuggin passes with the mm210 cranked all the way up to fill up the chamfer I ground out...that was a pain.....

[The BN Guy]

Looks good. I have a similar design drawn. Just need to build the danged thing.

Word of warning, don't know about your state but in Texas it is now illegal to have the air tank built into the bumper. Might want to check to be sure. The reasoning is to prevent further problems should you be involved in an accident.

[Scenic WonderRunner]

Looks Great!

Can you make me one of these>?!!!!!!:jumping: ....:D


http://staff.4x4wire.com/swilson/whatsnew/carrier.jpg
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(disclaimer!.......This is NOT my truck (although it's my exact model)....but this bumper sure would look good on my truck!)

[Willman]

Looks Great!

Can you make me one of these>?!!!!!!:jumping: ....:D


http://staff.4x4wire.com/swilson/whatsnew/carrier.jpg
.
.
.
(disclaimer!.......This is NOT my truck (although it's my exact model)....but this bumper sure would look good on my truck!)

SHOW ME THE MONEY!!!!!! Your not the first one to ask that question.....sounds like there is a little $$ to be made in this department!!! I would love to fab that up 4 U!! I would trade for one of those rooftop tents (or what ever you got) and or $$$. How does that sound??

[Willman]

Now it was time to work on the swing out gate to hold the tire. I had to see one of my buddies that had a tube bender. I used 1 3/4 pipe with a 1/8 wall (.120).
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01201.jpg
We bended the tube about 120 degrees....This pic we still have a few more degrees to go!! This tube bender was fresh from the box!!! Boy was it nice!!! All the bends were right on the $$$$$.
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01203.jpg
With one broken hole saw bit later..we had 2 awesome looking fish mouths....(Note to self...need to buy a tube notcher..while i got the wallet out a tube bender as well....) Having the drill press was the ticket!!!
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01204.jpg
With everything all layed out on the floor....just about ready to weld!!!
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01205.jpg
:D

[Willman]

I thought i would get you vote and reason why on if the tire should be to the right or center????

(note..due to the reciever hitch..i had to flip the bumper to plan this out.)
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01208.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01209.jpg

I will go first....I think i should put it to the right...Then i can still some what use my rear view mirror. Plus i have more room on the left side for gas cans and other stuff.

What do you guys think????

[erin]

:coffee:
Very nice design. I would keep the tire closer towards the hinge in order to keep stress off it as much as possible. that way the spare willl always be on, and you can just put on the cans for trips.

[goodtimes]

I would put it as close to the hinge as possible, and as far to the drivers side as possible. This will keep the leverage on the hinge down, and let you use your rear view window.....of course, that also means that it swings from the drivers side. Not sure why everyone builds them to swing from the passenger side (like you did....and I did the first time I built one....)

[calamaridog]

This information may not apply directly to your build but I like to post it for general information...

Error on the side of caution and have a failsafe design. Loosing the tire carrier on the fwy could easily result in GBI or death for someone behind you.


Rear tire carrier design FAQ
Originally posted by Tankota (TTORA)

"That's the same exact type used on my old one. They are using mini axle spindles, kind of like you would use on a small trailer. They are plenty strong as is, but the weak point is where it's mounted to the bumper. The stub is usually hardened, and when they weld it to the bumper it weakens them at the base. Then the light rocking back and forth of the tire on the gate over time causes fine fatigue cracks at the base, and eventually it goes all the way through the spindle. It all depends on how well they are controlling the bouncing of the gate, and how good their welding is. If you are driving down the road and you can see the tire moving front to back at all, then it's flexing at the base, and over time will cause the metal there to weaken and fail. Kind of like bending a paper clip back and forth. The more the movement, the faster it will break.

Some of the Jeep bumpers have a latch higher up, and this works well to control the movement. If you look at some designs, all the weight is hanging off the gate at an offset (tire), and the mounting points are all below the gate at the base, with nothing to stop movement at the top.

This is the reason when I built my new rear bumper I used 2 hinges, and 2 latches. It's not as low profile and clean as those types, but it stops the movement, even while off-road. Plus it's almost impossible to have both both hinges and both latches fail at the same time. Mine's way overbuilt, I sat there making sure almost everything had at least 2 attachment points. That way if I start to have any problems I can catch it before hand.
Now there are plenty of bumper built that way that never have this problem. I'm sure that's a very nice high quality bumper, and I have no knowledge of any from that company having problems. But I have heard of at least 6-7 built with that type of hinge that have failed, in addition to mine, and that's just from 1-2 message boards so who knows how many have had problems that never made it onto those 1-2 message boards. This problem is very hard to detect ahead of time, you have to remove the entire gate and bearings and examine the base of the spindle where it's welded to the bumper and look for hairline cracks. This type of failure could take months, years, or never. Mine was about 2-3 years old when it failed."

[elcoyote]

My vote puts the tire to the right side of the bumper for 3 reasons:

1- When you get a flat you pull off the road, the tire will be accessible from the passenger side, not the traffic side which would present a higher risk of getting hit by vehicle.
2- I have seen many a time when a trailer hitch and spare tire interfere with each other, putting it off to the side minimizes that problem.
3- I agree with keeping the stress closer to the hinge to minimize the fulcrum effect on the spindle and welds.

Nice looking set up, thanks for sharing your fabrication journey with us! Looking forward to the pictures of it covered in dirt:D

[Willman]

This information may not apply directly to your build but I like to post it for general information...

Error on the side of caution and have a failsafe design. Loosing the tire carrier on the fwy could easily result in GBI or death for someone behind you.


Rear tire carrier design FAQ
Originally posted by Tankota (TTORA)

"That's the same exact type used on my old one. They are using mini axle spindles, kind of like you would use on a small trailer. They are plenty strong as is, but the weak point is where it's mounted to the bumper. The stub is usually hardened, and when they weld it to the bumper it weakens them at the base. Then the light rocking back and forth of the tire on the gate over time causes fine fatigue cracks at the base, and eventually it goes all the way through the spindle. It all depends on how well they are controlling the bouncing of the gate, and how good their welding is. If you are driving down the road and you can see the tire moving front to back at all, then it's flexing at the base, and over time will cause the metal there to weaken and fail. Kind of like bending a paper clip back and forth. The more the movement, the faster it will break.

Some of the Jeep bumpers have a latch higher up, and this works well to control the movement. If you look at some designs, all the weight is hanging off the gate at an offset (tire), and the mounting points are all below the gate at the base, with nothing to stop movement at the top.

This is the reason when I built my new rear bumper I used 2 hinges, and 2 latches. It's not as low profile and clean as those types, but it stops the movement, even while off-road. Plus it's almost impossible to have both both hinges and both latches fail at the same time. Mine's way overbuilt, I sat there making sure almost everything had at least 2 attachment points. That way if I start to have any problems I can catch it before hand.
Now there are plenty of bumper built that way that never have this problem. I'm sure that's a very nice high quality bumper, and I have no knowledge of any from that company having problems. But I have heard of at least 6-7 built with that type of hinge that have failed, in addition to mine, and that's just from 1-2 message boards so who knows how many have had problems that never made it onto those 1-2 message boards. This problem is very hard to detect ahead of time, you have to remove the entire gate and bearings and examine the base of the spindle where it's welded to the bumper and look for hairline cracks. This type of failure could take months, years, or never. Mine was about 2-3 years old when it failed."

Thanks for the infor!!!! I am planning a second safety latch that will behind the bumper just incase some thing goes wrong...I'm going to have to check in on how or if the steel of the hinge is hardened or not...Again..thanks for the great infor.!!!

[Willman]

I would put it as close to the hinge as possible, and as far to the drivers side as possible. This will keep the leverage on the hinge down, and let you use your rear view window.....of course, that also means that it swings from the drivers side. Not sure why everyone builds them to swing from the passenger side (like you did....and I did the first time I built one....)

Thanks guys for all the input!!!!

It's still not to late to change sides for the tire gate!!! I have not welded the pin in yet...I can plug those holes and drill a new one on the other side pretty easy!!!! Good point on the rear view mirror thing!!!

elcoyote also had a really good reason for the tire carrier being on the left side for not getting hit by another driver.....

I'm going to have to think about this one!!!!! :coffee:

[goodtimes]

elcoyote does make a good point about having it swing from the passenger side...it will swing away from traffic if you are pulled off to the side of the road. Upon further consideration, I would definately keep it where it is...swinging into traffic is just not good.

[Willman]

It might be hard to look over my shoulder being on the right side....but if it keeps me out of harms way, i will deal with it!!!!!

Thanks for all the input!!!!!!! :clapsmile

[goodtimes]

Can you move the tire lower on the carrier? (IE: closer to the ground)

At some point it becomes problematic on the trail (tire hanging up on ledges as you drop over them), but how much so will depend on the kinds of trails you travel on. I would put it as low as possible to allow the best visibility, until it is so low that it starts to become a problem on the trail. A good set of mirrors will become your friend with a tire mounted up high like that.

[Willman]

Can you move the tire lower on the carrier? (IE: closer to the ground)

At some point it becomes problematic on the trail (tire hanging up on ledges as you drop over them), but how much so will depend on the kinds of trails you travel on. I would put it as low as possible to allow the best visibility, until it is so low that it starts to become a problem on the trail. A good set of mirrors will become your friend with a tire mounted up high like that.

Thanks for the info!!

I'm going to put it as low as poss. w/out causing it to drag on things..I can't put it to low anyway..it would block the plans for my shackles! That is coming soon!!!

[flyingwil]

You done with thing yet? Or still looking for input?

[Willman]

You done with thing yet? Or still looking for input?

No...I'm ending the road of input.......Thanks for asking.....Now i just need time to put the rest together!!! I have decided to keep the tire to the right side and put it low as i can get it. I work fulltime and go to school fulltime..alot of my time is in my books!!! :coffee: There will be some updates coming soon with pictures....Thanks!!

[flyingwil]

I threw in some comments on TTORA voting for the right side to counteract the weight of the fuel and battery, also the stress points as also point on on this forum.

While you still have it as is, you might think of adding a coupler similar to a trailer hitch that you fabbed up to mount to swing gate. Then make a bracket (Receiver) for Jerry cans and another bracket for ammo cans... I know you mentioned debating those two, so that way it would be versatile and you have the option of both. Make it an adapter similar to the trailer hitch adapters then it becomes more universal. If you go this route you would want a cover, and plugs, or drainage holes for water.

[Willman]

I threw in some comments on TTORA voting for the right side to counteract the weight of the fuel and battery, also the stress points as also point on on this forum.

While you still have it as is, you might think of adding a coupler similar to a trailer hitch that you fabbed up to mount to swing gate. Then make a bracket (Receiver) for Jerry cans and another bracket for ammo cans... I know you mentioned debating those two, so that way it would be versatile and you have the option of both. Make it an adapter similar to the trailer hitch adapters then it becomes more universal. If you go this route you would want a cover, and plugs, or drainage holes for water.

I agree totally!.......Great idea on the jerry cans/ammo box thing!!! Thanks...I will have too think about that one!!!

[Willman]

Here is the pin installation of the hinge. I assemble the hinge on the swing-out gate arm/pin and all. I took a piece of fire banket to protect the upper part of the pin..... Placed it in the hole and ticked it on the bottom. Then removed the swing-out arm and ticked the top.....Then i double checked it...making sure i was still plum.......Then welded it all up.......

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01227.jpg

All welded up and ready to cut the end off and grind the bottom.

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01228.jpg

Boy.......this is a nice setup for a hinge!!! It swings like butter!!!! The only thing i might do is add another gussit to the bottom of the hinge where the arm meets.

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01231.jpg

[OldSven]

So is this thing going to be done by summer:shakin:

[Willman]

So is this thing going to be done by summer:shakin:

Its like the little train that could!!!! Having a schedule like mine doesn't help at all!!!!!! Sorry for the SLOW buildup.......but that why i called it a buildup!!!!..................lol

Back at U.......:shakin:

[OldSven]

So getting off of work at noon doesn't help to much does it:xxrotflma How does an I-90 night run sound this weekend?

[Willman]

I used 3/8 plate steel for the mounts and drilled a 9/16 hole for the 1/2 bolts. I had my vise sitting around my shop and no where to put it...So i placed it on a sawhorse which worked out very well for misc. cutting and grinding.

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01246.jpg

Welding on the piece of L metal to the mount to add more beef to the pile!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01253.jpg
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01255.jpg

Now it was time to place the mounts on and tac on the bumper in place

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01256.jpg

After that...pulled it off and welded it all up

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01257.jpg

My good friend came to dust-off has great welding skills and helped out in the mounting process....This was a two person job getting it all plum!!!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01258.jpg

Added 3/8 gisits to both inside mounts...

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01259.jpg

Then we put it back on the truck to work on the tire carrier.....The bumper fitted like a glove!!!!! Using my cardboard cut-out...I layed-out where my 1 3/4" tube should go to support the tire.....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01260.jpg

I am very proud of this fish mouth!!!!! Not to bad with a drill motor w/ a hole saw!!!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01262.jpg

[OldSven]

So is it mounted up yet???

[Willman]

It was getting late..(2 am)...so we called it a night! Here is what we got done!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01264.jpg

The hinge works VERY well!!!! So far i am very pleased with it....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01267.jpg

A lot to do.....
-make mount for tire
-add D ring tabs that weld on both sides of bumper..
-toggle clamp
-swing-out stop plates on both ends......and the list keeps going!!!

[OldSven]

A few more hours and it will be done. We'll go see how it holds up on the trail next weekend.

[flyingwil]

A few more hours and it will be done. We'll go see how it holds up on the trail next weekend.

Wow your pretty optimistic on this build up! At this rate it'll be on there in about 7 more weeks! lol:shakin:

[Willman]

Both you guys are always welcome to come help out!!!! (Flyingwil,Oldsven)....................lol........ .......
:ar15: --------------------------- :shakin:

This will be me at Lake Powell in week and a half!!!!.....How do you like em apples?????
:suning:

[OldSven]

Well that adds up to 8 1/2 weeks to go:sport_box If you want me to come over Friday night and help you finish it, let me know. That will free you up to go to Rieter Saturday morning.

[Willman]

Well that adds up to 8 1/2 weeks to go:sport_box If you want me to come over Friday night and help you finish it, let me know. That will free you up to go to Rieter Saturday morning.

Thats going to be one long night!!!!! :smileeek:

(Oldsven-Laptop works great, anywhere in the house!!!!!!)

[OldSven]

Let's get the bottom part done first. Get the d-ring mounts welded, get the toggle switch on, and paint it. The tire part can be done separte. we will just get the main part taken care of Friday. Just get all the part's ready to go and get as far as you can this week. I'm going to see who all I can round up for Saturday. I would like to head up Issabell and hopefully the Index wall. It will be a good day to put the sliders to use.:D

[Willman]

Hey Flyingwill........Oldsven is coming......Are going to make the trip up from AZ to help out and do a little wheeling after??????...................lol
:D

[Scenic WonderRunner]

Check out this kewl bumper I found over at Yotatech this morning.

I like the recessed lighting and receiver......and the tow points.

I think you still have time to do some lighting there Willman! .....:ylsmoke:


http://www.polaris-ranger-parts.com/images/tellico5-11-06/4runners/dsc00129.jpg

[Willman]

Nice find ScenicWonderRunner!!!! Still thinking about the lighting thing...The air tank idea has made things a little harder......but will pay off with the saved space under the bed.....After i get my D-rings in......recessed lighting isn't a bad idea!!!!...Down the road i need to add rock lights.....and the list goes on........

[OverlandZJ]

I'v been meaning to post my compliments Willman, solid work! :victory:

Too bad your located on the wrong coast...i'd have you build me a new swingaway configuration. ;)

[Willman]

I'v been meaning to post my compliments Willman, solid work! :victory:

Too bad your located on the wrong coast...i'd have you build me a new swingaway configuration. ;)

Thanks man!!! Maybe someday you might move over here were the grass is greener!!!!...Thats if you don't mind the rain!!! :D ......lol

[Willman]

I got a piece of 1/2" plate steel......Drilled a 7/8" hole for my 3/4 shackles..Boy did these babies turn out great!!! Heres some pic.....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01272.jpg

Got the torch out and went to town.....Preheated the steel ........she cutted like butter!!! For max. strenght...Due to the tube...I wanted to pull on both sides of the tube walls instead of just welding on a tab....Thats why they look like a key....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01275.jpg

layed out the spot for the D-rings and torched out on both sides.......Then i took a die grinder to reach inside to hole to clean it up a touch.....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01277.jpg

Before i welded them in.....Took my shopvac and got all the welding/cutting slag out from inside the bumper. I taped a piece of 1/2"x3' tube to the hose to reach all the way to the bottom....Getting ready for the Air tank!!!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01278.jpg

Cleaned up all the edges........ready to weld them in....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01279.jpg

heres the final product!!!!! Not to bad!!!!......having a bench grinder really helps.....If you don't have one already....put it on your tool list!!!!! It's great to have around!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01281.jpg

[Ramdough]

NICE Bumper!!!:clapsmile :clapsmile :clapsmile

I hope I did not miss this, but are you planning on putting rear sliders on that bumper?

I highly recomend them if your friend has time to bend you some more tubes.

Check out Scott's, Baja's, Mine, DO's bumpers for ideas if you are going to do this. Mine have saved my butt a few times.

[Willman]

NICE Bumper!!!:clapsmile :clapsmile :clapsmile

I hope I did not miss this, but are you planning on putting rear sliders on that bumper?

I highly recomend them if your friend has time to bend you some more tubes.

Check out Scott's, Baja's, Mine, DO's bumpers for ideas if you are going to do this. Mine have saved my butt a few times.

Thanks!!!

I plan on adding the rear sliders!!! That is a must have!!! The sliders will make a great finishing touch!!!!

[Willman]

This is all my toggle hareware.....I made a backing plate and another backing plate for the lower part of the toggle....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01320.jpg

I put the toggle clamp on and decited to recess it in to pull the arm in and down on the rubber...this will keep it from going any where!!! I am planning a 2nd clamp down the road...maybe i will put a lock on that one to keep people out and a piece of mind in case the first toggle clamp comes open while going down the road!!!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01321.jpg

All i need to do is drill and tap the holes to mount the clamp!!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01322.jpg

Now time to mount the tire piece......I took a piece of 1/4" plate to make up the 8" round plate to hold the lug bolts and welded them in place....Then it was time to weld the "L" piece to the swingout gate.....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01323.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01324.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01325.jpg

Now i need to add gessits to the swingout gate and the "L" tire mount to beef it up....That tire fits on there like a glove!!!! I am very happy how the tire looked mounted!!!! Everything came out as planned!!!!! Now time to add my HI-LIFT (still need to buy..) mounts that will run above the swingout gate at somewhat at a 45^ angle....

[Ramdough]

Willman,
That bumper is looking good! :clapsmile

I have a question though, I do not see wich direction the toggle pulls on the gate.

Does the toggle the gate down or does it pull the gate toards the front of the vehicle?

BTW, Where did you get your latch? Is it stainless.... it looks like it.

I need to get 2 for my design.

[Willman]

Willman,
That bumper is looking good! :clapsmile

I have a question though, I do not see wich direction the toggle pulls on the gate.

Does the toggle the gate down or does it pull the gate toards the front of the vehicle?

BTW, Where did you get your latch? Is it stainless.... it looks like it.

I need to get 2 for my design.

Thanks again!!!!! I love your roof-top tent by-the-way.....nice website!!!!!...
On the other hand......

The Toggle clamp is stainless steel...
http://www.mcmaster.com/
pg 2448 item # 51335A68
It's about $67.50....but worth it!!!

The toggle pulls down and in on the piece of L metal that i welded for a stop with a rubber piece between the gate and top of bumper (I will post a pic of that soon). Doing this keeps the gate locked down from moving around.

Check this website out for more toggle clamp pics...3/4 down, red landcriuser!!!
http://4rnr.net/exterior

[Ramdough]

Thanks,

Hey what size bolts did you use for the tire carrier (studs)?

I need to buy some soon... construction on my tire (http://www.expeditionportal.com/forum/showthread.php?t=1328) carrier starts this week.

Thanks .

[Willman]

Thanks,

Hey what size bolts did you use for the tire carrier (studs)?

I need to buy some soon... construction on my tire (http://www.expeditionportal.com/forum/showthread.php?t=1328) carrier starts this week.

Thanks .

I forget...Just go to Napa(or any other parts store) and tell them what rig you have and they will have that stud. Make sure to get the rear studs, because i guess the front are a little shorter???? Thats what the Napa guy said???? I would not take his word for it!!!! Something to think about...either stud should work front or rear!!!!.....Good luck with the buildup!!!

[HenryJ]

Something to consider-
When I modified my tire carrier I too used the same wheel studs that my truck uses. I did not weld them in place. This would allow me to knock them out and replace a damaged wheel stud in the field should the need arise. With my drop down bracket I have six spare wheel studs back there :)

[Willman]

Something to consider-
When I modified my tire carrier I too used the same wheel studs that my truck uses. I did not weld them in place. This would allow me to knock them out and replace a damaged wheel stud in the field should the need arise. With my drop down bracket I have six spare wheel studs back there :)

Where were you about 2 days ago??? ....Well..as you read...i welded mine on.....oh well......I have sure learned a lot for everyones inputs...The next swingout will rock in the future!!!..I still have love for the one i'm building and the next one will be even better...Thats why i love working with steel....its changeable!!! Thanks for your two cents HenryJ!!!!....but for now...i will leave the studs as is. good point!

[Ramdough]

HenryJ
What size holes did you drill in the plate for the studs?

Did you press them in place or are they loose?

[Willman]

HenryJ
What size holes did you drill in the plate for the studs?

Did you press them in place or are they loose?

I drilled a 9/16 hole which worked great and fit a tiny-tiny bit loose!!!!!

[HenryJ]

I don't recall the hole size. Mine are likely different than others since I have a Chevrolet. They were a press fit. Snug in the plate.
I am sure the knurls would be compressed enough that they would not make a good permanent fix, but still way better than nothing in a pinch.

[Willman]

Drill and tapped a hole for my rubber vibration isolaters x2. I picked them up at Granger...They will workout great!!! I do not have a pic to it now...but will post one later...

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01390.jpg

Flush mounted a piece of 1" thick steel to hold the lower part of the toggle clamp in....Due to it being a air tank....I did not want to take a chance of the air leaking out of the screws...This way everything is 100% sealed!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01396.jpg

All welded in.....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01397.jpg

Now time to drill/tap a 1/4" hole for my SS screws....this was a long process....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01398.jpg

Then i had to go back and beef up the gate with some gissits....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01399.jpg

[Willman]

Here it is!!!!.....How i need to add my Hi lift jack mounts and paint it up!!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01401.jpg

[asteffes]

That is truly great work.

[p1michaud]

Here it is!!!!.....How i need to add my Hi lift jack mounts and paint it up!!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01401.jpg

Very very nice. I'd like some better quality pictures of the finished product once you have the time. A custom bumper in on my list of things to do.
Good job.
Cheers:beer: ,
P

[PCRover]

Looks great! I wish I had the skills to make someting like that, maybe some day...

[HenryJ]

Nice rack! http://www.s-10crewcab.com/phpBB2/images/smiles/icon_applause.gif

[Ramdough]

I will second the :clapsmile

great work!

[Willman]

Time to make my Hi-Lift mounts!! I used a piece of 3/16 and drilled a 1/2 hole for the mounting bolt.

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01406.jpg

Then for the bottom mount...I did the same as above and also welded in the 3/8 bolt on the bottom to hold the lift in place.

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01407.jpg

I bolted it all up to get the right angle i wanted and tacked it into place. The top mount i took a small square piece and welded a 3/8 bolt on to it. This would go on the other side so it will fit just right into the lift channel so the bolt doesn't spin around.

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01408.jpg

The gate is done!! Time to get it all cleanedup and ready to paint. I used a flap dish to get it all smoothed out. Used some brake cleaner to get it all ready to paint. I used the same process for the bottom bumper as well. Heres a pic of it with one coat of primer....

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01409.jpg

Now time for the air test on the tank!! This took a while! I drilled and tapped an air fitting on the bumper. I fired up my compressor (Engo construstion compressor not my portable one) which was able to pump it with about 150 PSI. Then i took soap and water all around the bumper finding all the SMALL holes and marked it with a pen. Then dropped down the air pressure to nothing in the bumper so i can fix all the holes. I grinded down a little on the holes and fulled it full of weld. This process took my about 3 times to get it 100% sealed up with no air getting away!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01411.jpg
http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01412.jpg

Then i added a 1/2" solid round stop so the tire on the gate does not takeout my tail light...

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01413.jpg

Then i put some 3/8" bent solid round stock for the chains for my trailer to go.

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01416.jpg

:victory:

[Willman]

Here they are!!!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01418.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01419.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01422.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01423.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01428.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01427.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01426.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01424.jpg

I still need to mount my plate & light, CB wip, and get my onboard compressor all wired up to full that tank!!!....My plate is going to go between the toggle clamp and the lift for now until i add some jerry cans in the future. I also need to add my side protection as well in the future...That will happen in a few months when summer school is done!!! I am very happy with the final outcome!! Now it is time to trail test it and get my clean truck all dirty!!!! Thanks to everyone who posted up and give your thoughts and opinons!!! You guys rock!!!!!

[p1michaud]

I still need to mount my plate & light, CB wip, and get my onboard compressor all wired up to full that tank!!!....My plate is going to go between the toggle clamp and the lift for now until i add some jerry cans in the future. I also need to add my side protection as well in the future...That will happen in a few months when summer school is done!!! I am very happy with the final outcome!! Now it is time to trail test it and get my clean truck all dirty!!!! Thanks to everyone who posted up and give your thoughts and opinons!!! You guys rock!!!!!

Very nice job. Your bumper came out nice. Thanks for the pictures and write up.
Cheers,
P

[Coachgeo]

Future addition

You might consider taking pressure off the hinge and add an extension (think shelf) off the actual bumper that sits just below the tire. Weld a big arse nut in the bottom center of it. Make a plate to sit above this. It just floats there. Place a bolt up thru the nut so it presses agains the floating plate. Put a big C clip on the bolt so it can spin but not allow the bolt and floating plate to seperate.

Why? ok.... after you swing the tire carrier closed you crank up the bolt which pushes the floating plate upward agains the bottom of the tire and WALLLA.... the tire's weight is now supported by the plate . This means the weight of the tire, etc. is no longer on the hinge, but on the more sturdy bumper itself. Weld a cheap socket and wrench to the bolt head for easy use. Mount a clip to hold the socket wrench handle up against the bumper.

Hope that makes since.

[PCRover]

Excellent job and thanks for the pictures! It's posts like this that inspire me to take on more projects myself rather than just buying off the shelf.

[Willman]

Future addition

You might consider taking pressure off the hinge and add an extension (think shelf) off the actual bumper that sits just below the tire. Weld a big arse nut in the bottom center of it. Make a plate to sit above this. It just floats there. Place a bolt up thru the nut so it presses agains the floating plate. Put a big C clip on the bolt so it can spin but not allow the bolt and floating plate to seperate.

Why? ok.... after you swing the tire carrier closed you crank up the bolt which pushes the floating plate upward agains the bottom of the tire and WALLLA.... the tire's weight is now supported by the plate . This means the weight of the tire, etc. is no longer on the hinge, but on the more sturdy bumper itself. Weld a cheap socket and wrench to the bolt head for easy use. Mount a clip to hold the socket wrench handle up against the bumper.

Hope that makes since.

Great Idea man!!!

I just trail tested it today!!! Like a dream!! Pictures coming soon!!! The hinge is very stout. Thanks for the idea..I think that would come in handy with a larger tire!!!

[Willman]

So far so good!!! I love my new rear bumper!! Here is some trail pictures from a weekend or two ago......Enjoy!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01457.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01463.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01474.jpg

The Best one for last!!! Mt. Rainier

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01466.jpg

[flyingwil]

Dude, way too cool! When are you going to start on mine? LOL

[Willman]

Dude, way too cool! When are you going to start on mine? LOL

I'm moving down to Utah this coming April!!!! I will have a lot more time on my hands plus have a HUGE shop to work in!!! We will have to talk!!!

[FlyingWen]

Awesome cool bumper. I love the swing out tire...!

Congrats on being a "New Dad"!

[3 DOGS]

If you do decide to start making these let me know...SERIOUSLY!!
You'll have to start figuring out pricing because I'm sure you'll get a lot of inquiries about making them.
You may have just started a money making business.
Very very very nice!!

03 Taco TRD, D-Cab, Snug Fit topper, Bed Rug, 265/75/16 Hercules Terra Trac AT - just getting started

[devinsixtyseven]

really nice job :D. cant wait til i get my welder...

here's a great tip on notching tubes...instead of hole-sawing a fishmouth, cut the end of the tube youre fitting to a point. youll need to work out the angle, but there are some calculators online for the angles if your joint is not 90*, even templates for the cut.

now turn it sideways...easy fishmouth :D. the curve of the tube provides the necessary curve for the joint, just needs a bit of touchup on a grinding wheel and it'll fit almost perfectly. all ya gotta do is cut a straight line.

-sean

[HongerVenture]

Very nice build-up. This has given me several ideas for my upcoming bumper. I'm still not sure if I'll make a swing-out or not, but I know that the rear quarter panels will need wraparound protection. Your swing-out is super trick and is seriously making me consider making that a feature.

I'd be curious to see more pics of your latching and securing mechanism (you mentioned rubber pads of some sort). Do you observe any "bouncing" of the tire as you drive off-road? Is there any forward-backward movement of the tire?

Again, it looks fantastic. I'm quite envious of your talent and skill with fabbing.:bowdown:

For other folks future reference, Slee offers a tire carrier spindle that I've heard glowing reports of. Click here to see that. (http://www.sleeoffroad.com/products/products_diy.htm)

[Willman]

Awesome cool bumper. I love the swing out tire...!

Congrats on being a "New Dad"!

Thanks and Welcome to the site!!!

Thanks all for the kind words and tips!!

[Willman]

I'm still not sure if I'll make a swing-out or not, but I know that the rear quarter panels will need wraparound protection. Your swing-out is super trick and is seriously making me consider making that a feature.

I'd be curious to see more pics of your latching and securing mechanism (you mentioned rubber pads of some sort). Do you observe any "bouncing" of the tire as you drive and off-road? Is there any forward-backward movement of the tire?

I have finished my rear quarter panel wraparound with 1.5" tube! Pictures to come!

The tire and gate does not move at all! It is very strong!!! I am 100% happy with the outcome and overall look!

[toyrunner95]

hey thats awsome, now i got some ideas for mine!

[java]

Very nice craftsmanship. If you do decide to start producing these before you move i would be very interested also!

[Willman]

Very nice craftsmanship. If you do decide to start producing these before you move i would be very interested also!

Thanks! The idea has passed through my mind....too busy with school....Keep you all posted....

I need to add the updated pictures of the new side protection...coming soon!!

:elkgrin:

[Willman]

Here's the new side protection! Made out of .120 1.5" HREW tube.
I have already put it to good use!!! It turned out great!!!

http://i51.photobucket.com/albums/f374/nicwillman/DSC02197.jpg

http://i51.photobucket.com/albums/f374/nicwillman/DSC02198.jpg

:jumping:

Now time to get the air tank all plumbed up to my future high output compressor.....coming soon!

;)

[flyingwil]

http://i51.photobucket.com/albums/f374/nicwillman/DSC02198.jpg


Outstanding work! :bowdown:

[p1michaud]

Here's the new side protection! Made out of .120 1.5" HREW tube.
I have already put it to good use!!! It turned out great!!!

http://i51.photobucket.com/albums/f374/nicwillman/DSC02197.jpg


Nice work. I'm currious if you tied in the front sections (i.e. closest to the tire) to the frame?
Cheers :beer:,
P

[Willman]

Nice work. I'm currious if you tied in the front sections (i.e. closest to the tire) to the frame?
Cheers :beer:,
P

In the center of the lower tube, their is a support going back to the frame. Don't have a good picture right now....the truck :safari-rig: is 800 miles away....Post one when i return from UT.

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/P1010008.jpg
(you can barely see it, better picture coming soon)

:REOutIceFishing:

[Willman]

Nice work. I'm currious if you tied in the front sections (i.e. closest to the tire) to the frame?
Cheers :beer:,
P

Here you go....

http://i51.photobucket.com/albums/f374/nicwillman/DSC02391.jpg

[Schattenjager]

Show Off! PUNK! I AM SOOO JEALOUS!!! ;)

Take it from a guy who can barely tie his own shoes yet appreciates a quality vision and implementation: JOB WELL DONE! You have remarkable talent for craftsmanship and a great eye for design. Punk...

:friday:

[Willman]

Show Off! PUNK! I AM SOOO JEALOUS!!! ;)

Take it from a guy who can barely tie his own shoes yet appreciates a quality vision and implementation: JOB WELL DONE! You have remarkable talent for craftsmanship and a great eye for design. Punk...

:friday:

Thanks my Punk friend!!!...lol

:steak:

[p1michaud]

Here you go....

http://i51.photobucket.com/albums/f374/nicwillman/DSC02391.jpg

Job well done. I was wondering how you tied in the sides. They should hold the weight of the truck if you need to jack from the side.

Thanks for the pic.

Cheers,
P

[RoundOut]

Well done. That is magnificent craftsmanship and totally functional. I learned so much from this thread!

[Willman]

Well done. That is magnificent craftsmanship and totally functional. I learned so much from this thread!

Thanks for the kind words!!! Let me know if you have any questions!!!

And Welcome to the ExPo!!!

:elkgrin:

[crawler#976]

Nice job!

I notice folks asking how much it would cost to produce a similar bumper. Having built mine (less swingout or side guards) a couple months ago, I can say that at least for my skill level it'd be way to expensive to sell. Material wise I ended up at $210.00 for reciever, D'Rings, 6 feet of 0.25 wall 2x6, and 4 feet of 3/8 x 6" steel, hardware, and primer/top coat. Time wise it took most of 4 weekends - planning/layout, fabrication, painting, and installation had to take nearly 40 hours.

So, to put it conservatively, I built a simple bumper at would cost you $1100.00 to pay me roughly my current wage.

None of my tools or perishable items are included in that either - welder, saw, sawzall, grinders, wheels, saw blades, mig wire, CO2, safety glasses, etc.

Obviously, it would be less the second time around (if I'd kept my prints/layout stuff), and with the addition of a plasma cutter to my current tools, I could do it much faster. (It took hours to saw the angles and mounting brackets with a sawzall in 0.25 wall and 3/8" stock - and nearly $40.00 in blades!!!)

But, my time is free for my own projects...and I really enjoy fabrication, so it's well worth the time and effort involved.

Mark

[Willman]

Nice job!

I notice folks asking how much it would cost to produce a similar bumper. Having built mine (less swingout or side guards) a couple months ago, I can say that at least for my skill level it'd be way to expensive to sell. Material wise I ended up at $210.00 for reciever, D'Rings, 6 feet of 0.25 wall 2x6, and 4 feet of 3/8 x 6" steel, hardware, and primer/top coat. Time wise it took most of 4 weekends - planning/layout, fabrication, painting, and installation had to take nearly 40 hours.

So, to put it conservatively, I built a simple bumper at would cost you $1100.00 to pay me roughly my current wage.

None of my tools or perishable items are included in that either - welder, saw, sawzall, grinders, wheels, saw blades, mig wire, CO2, safety glasses, etc.

Obviously, it would be less the second time around (if I'd kept my prints/layout stuff), and with the addition of a plasma cutter to my current tools, I could do it much faster. (It took hours to saw the angles and mounting brackets with a sawzall in 0.25 wall and 3/8" stock - and nearly $40.00 in blades!!!)

But, my time is free for my own projects...and I really enjoy fabrication, so it's well worth the time and effort involved.

Mark

Nice!!! Thanks for your input!!

Sawzall.....Really not my choice in tools....I'm a torch kind of guy!!! A plasma cutter is what i'm talking about!!! That's on my tool list!!! That will really speed things up!!!

A bumper like mine....The air tank part was the most timely for me....making sure that all was sealed and pressure tested takes time (150 psi)....The main part of the bumper, side protection and the tire gate did take some thinking out...but all came together in a timely order.....I have learned sooo much from this build to take to the next swing-out rear bumper!

This bumper took me some time to build due to my schooling!! If i just had to work and not go to school, i could have this hammered out in two weeks working on it after work....I would say i have about 40-55 hours in this bumper. Another thing that killed me on time was building it in my carport...having a garage you can just drop everything and pickup fabbing later...whereas having the carport i would have to bring out and put away everything to be able to keep my stuff safe.

The price tag......A bumper like mine.......I would say around $1000-$1200 roughly...

Doing fab is alot of fun!! I enjoy working with metal.....Getting a TIG welder soon to really make things look pretty!!!

[devinsixtyseven]

So, to put it conservatively, I built a simple bumper at would cost you $1100.00 to pay me roughly my current wage.I can tell ya from experience that's a fair price and probably on the low side, and the parts to labor ratio is about right as well. My rear bumper, if I had not done a majority of the initial design, cutting, fitment and other stuff, would have run close to 2K$.

To really get the most of this DIY without a welder, gather the material and cut everything, even tack it yourself, then take it to an accomplished craftsman for final welding.

it's the fitment, prep and cleanup, cutting and such that takes the bulk of the time, and that's something a guy can do himself, then leave the assembly to someone with the appropriate skills.

From my own experience, my rear bumper cost under 100 bucks in materials, but because I wound up with an ambulance trip and unable to do anything for a month, I had to pay someone else to do final assembly as well as welding and the price tag was not low...and he even cut me a break. The welding time wasn't much, but the grinding, fitment, all the little stuff...it adds up in a hurry. What could have been a 200$ project increased significantly when I had to pay someone else to do the small stuff.

Save your money for the welding if you don't have a rig yourself, and spend money on an angle grinder, sawzall, body saw, metal, and maybe a handy CAD program or just some pencils and graph paper.

-Sean

[Willman]

To really get the most of this DIY without a welder, gather the material and cut everything, even tack it yourself, then take it to an accomplished craftsman for final welding.

it's the fitment, prep and cleanup, cutting and such that takes the bulk of the time, and that's something a guy can do himself, then leave the assembly to someone with the appropriate skills.

-Sean

What do you mean????

Welding it all up is the best part of the buildup!!! Welding is what i live for!!!! Do you not trust yourself with a welder or do you have little to no experience welding???

You could save yourself alot of time and $$$$$ by welding your own material if you have all the supplies like welder, torch, etc.... Sounds like you have a welder....Do you only have a 110 wire feed??? Most cases depending on thickness of your material and the wire you are running a 110 will do the trick!!!

Just my 2 cents....

:ylsmoke:

[devinsixtyseven]

Welding it all up is the best part of the buildup!!! Welding is what i live for!!!! Do you not trust yourself with a welder or do you have little to no experience welding??? :bigbossHL: I agree 100%! I was using the third-person "you", not you you ;). My suggestions were for guys building it themselves without access to a welder...that was my situation last summer and it worked out very well, since I had access to all the shop toys but wasn't used to the glue gun yet.
You could save yourself alot of time and $$$$$ by welding your own material if you have all the supplies like welder, torch, etc.... Sounds like you have a welder....Do you only have a 110 wire feed??? Most cases depending on thickness of your material and the wire you are running a 110 will do the trick!!!NOW I have a welder :D...as I work through this pile of scraps making practice welds to get a feel for speed/feed/heat settings for different materials, I'm also cutting/grinding/tacking up a welding table so I can stop working on the garage floor :p.

If you have a 4.5" grinder, a sawzall and a welder, you can do an awful lot on your own, I totally agree. Without the welder (not cheap, compared to the other two), a guy can do almost everything and then have someone with a rig glue it together :). My welds on larger material are currently :smilies27, I have a lot of practicing to do :D.

[Willman]

:bigbossHL: I agree 100%! I was using the third-person "you", not you you ;). My suggestions were for guys building it themselves without access to a welder...that was my situation last summer and it worked out very well, since I had access to all the shop toys but wasn't used to the glue gun yet.NOW I have a welder :D...as I work through this pile of scraps making practice welds to get a feel for speed/feed/heat settings for different materials, I'm also cutting/grinding/tacking up a welding table so I can stop working on the garage floor :p.

If you have a 4.5" grinder, a sawzall and a welder, you can do an awful lot on your own, I totally agree. Without the welder (not cheap, compared to the other two), a guy can do almost everything and then have someone with a rig glue it together :). My welds on larger material are currently :smilies27, I have a lot of practicing to do :D.

Right on man!!! Keep practicing!!!! Building a welding table is a perfect start ! love to see some pictures when your done!

Here is a great link on welding!

http://home.4x4wire.com/deddleman/section_welders.html

Enjoy and keep it up!

:clapsmile

[gemini97424]

Great looking bumper, I have one quite similar which I had fabricated at a shop in Huntington Beach, CA when I in So CA. I had a pair of sliders welded to the frame and the bumper built for less than $700. I did have a serious problem with porpoising when driving at highway speeds because of the added weight, ie, a shell weighing 400 plus pounds then a 32 X 11.50 tire, 5 gallons of gas and a hi lift jack, to much weight beyond the rear axle and bumper. To solve the problem I ended up going to Deaver Spring in Santa Ana and had a ten leaf spring pack made for the rear. Here are a few pictures:

[BigAl]

I just read thru your build, nice job:), a little slow:p . I saw the never ending debate on trailor spindles reared it's ugly head. I've never seen one fail, I've beaten on mine for 2 years now with now issues, but one thing I did to address the issue was use a more bombproof latch. I figure if the hinge lets go, it's unlkely that the grade 8 1/2" bolt in the latch will fail at the same time. I used this design from atoZ fabrication http://www.atozfabrication.com/catalog/images/atoz/thandle.jpg It also limits vibs better, IMO

[Willman]

I just read thru your build, nice job:), a little slow:p . I saw the never ending debate on trailor spindles reared it's ugly head. I've never seen one fail, I've beaten on mine for 2 years now with now issues, but one thing I did to address the issue was use a more bombproof latch. I figure if the hinge lets go, it's unlkely that the grade 8 1/2" bolt in the latch will fail at the same time. I used this design from atoZ fabrication
http://www.atozfabrication.com/catalog/images/atoz/thandle.jpg
It also limits vibs better, IMO

Thanks guys for the kind words guys!...Yes the build was a little slow...but working, having a family and going to college at the same time will do the trick:shakin:

So far...no problems with the hinge setup!......I put 2 rubber vibration isolators to help take some of the load off the gate.......I think this is the key to this setup!

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01427.jpg

:)

[heeltoe989]

Very Cool and a killer bumper!!

[Northern Explorer]

Great build!!! I really wish I knew how to weld. Bonus points for your truck being red. :jumping:

[Willman]

Thanks guys!

:)

[FlyingWen]

Hey Nic while you're at it. I'd like this bumper pictured below.
My B-day is January 30th...I'll be 30 too....
http://i69.photobucket.com/albums/i72/nanuk2121/X.jpg


I'll give ya a cookie!
That would be a super present....:hehe: :hehe:

[Willman]

Hey Nic while you're at it. I'd like this bumper pictured below.
My B-day is January 30th...I'll be 30 too....
http://i69.photobucket.com/albums/i72/nanuk2121/X.jpg


I'll give ya a cookie!
That would be a super present....:hehe: :hehe:

PM sent!......lol

That bumper looks really easy to build!.......I couldn't let you leave without side protection on that sweet "X" of yours!

When I'm out of school and if you still don't have a bumper......we'll talk!

;)

My Birthday is Dec. 6.........What are you getting for me????......lol

[3trdmarine]

Very nice bumper! I noticed your shackles, my old roommate made those :costumed-smiley-007

[Willman]

Very nice bumper! I noticed your shackles, my old roommate made those :costumed-smiley-007

Thanks!.....From the picture above...looks like you have a rock'in ride yourself!

Your roommate was from China? :shakin:


Haha!


On another note about the bumper...


Getting ready to cut about 3/4 off my gates length.....Need more room for the trailer so i can open my gate all the way!

Plus add a LightForce bolt on Stubby light (http://www.sierraexpeditions.com/index.php?l=product_detail&p=372)to the gate!


:camping:

[KG6BWS]

hi guys. ive been lurking for quite awhile but havent posted yet. thought this would be a good first one. im one of those people who have had the rock logic hinge fail. going down the freeway one day, the only thing that kept my tire, hilift, and 10 gallons of gas from going through the windshield of the car behind me was a 1/2" safety pin i had made. the hinge had fatigued right at the shoulder that the lower bearing sits on. if youre dead set on using the hinge (which works really well, as far as the movement goes, swung very nicely even with a 32" bfg m/t, 10 gals. of gas in steel cans and a 60" hilift on it) then make sure that there is absolutely no movement in the carrier when its closed, and use a safety pin (preferably 2, one at each end of the carrier). i think that the reason mine broke was because i had about an 1/8" of play up and down in it, and the hinge wasnt strong enough to prevent forwards and back movement when bouncing around offroad. my reccomendation would be to go with a hinge setup closer to the expeditionswest tacoma. to me that would prevent much of the movement that caused to fail.

[Willman]

^Welcome to the ExPo!


hi guys. ive been lurking for quite awhile but havent posted yet. thought this would be a good first one. im one of those people who have had the rock logic hinge fail. going down the freeway one day, the only thing that kept my tire, hilift, and 10 gallons of gas from going through the windshield of the car behind me was a 1/2" safety pin i had made. the hinge had fatigued right at the shoulder that the lower bearing sits on. if youre dead set on using the hinge (which works really well, as far as the movement goes, swung very nicely even with a 32" bfg m/t, 10 gals. of gas in steel cans and a 60" hilift on it) then make sure that there is absolutely no movement in the carrier when its closed, and use a safety pin (preferably 2, one at each end of the carrier). i think that the reason mine broke was because i had about an 1/8" of play up and down in it, and the hinge wasnt strong enough to prevent forwards and back movement when bouncing around offroad. my reccomendation would be to go with a hinge setup closer to the expeditionswest tacoma. to me that would prevent much of the movement that caused to fail.

This is great infor. for people in building their bumpers...I get a lot of people asking questions about my build....

My gate is totally solid!....Having a 255, 48" HL, is just right for the spindle......But putting 10 gallons of gas puts it over the edge in my opinion even with a solid gate! I totally agree....The Expedition West Taco's gate is the way to go if you want to carry that much weight!

[Willman]

With getting the trailer.....I didn't design my swing gate for the trailer....my swing-out gate was hitting the front of my AT holders....

http://i51.photobucket.com/albums/f374/nicwillman/Trailer/DSC04362.jpg

Well.....Got out the tools and went to work!...Felt good to put the books down and pickup the welder again!

I got a pull pin from Mcmaster Carr to hold the gate in place....Then i welded some flat bar to keep the gate from hitting the truck......I then cut a key hole in the flat bar so i could mount a tab with a hole in it for a lock.

http://i51.photobucket.com/albums/f374/nicwillman/DSC05838.jpg

Problem solved!...

http://i51.photobucket.com/albums/f374/nicwillman/DSC05835.jpg

I still need to cap the gate tube and get it ready for paint....More to come!

[4307]

Ah! good to know Will. ;) Out of curiosity, what's the distance between the tailgate and the area of gate contact on your trailer?

Still designing my swing out, this mod will help me rethink my design.

[OldSven]

Hey, no more jack knif'in the the trailer at camp:luxhello: Did you finish it last night?

[Willman]

^^^^Yes stir!...2 am baby!....I worked on this project and installed a hitch on my trailer.

He she is!...20 minutes using a 7 1/2" grinder to take off the old latch with the angle iron on it....My hands still hurt!

Before:

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01418.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC01427.jpg

After:

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC05874.jpg

http://i51.photobucket.com/albums/f374/nicwillman/Rear%20Bumper%20Buildup/DSC05873.jpg


Overall......I'm really happy with the outcome!....I love having the extra security with the lock on the gate....Just makes it even harder to break-in the canopy!

:)

[OldSven]

So with the pin is it as tight of fit as with the old latch? I like the lock idea too!!!

[Willman]

So with the pin is it as tight of fit as with the old latch? I like the lock idea too!!!

Yes it is....The pin does a great job holding it in place (side to side movement) and the lock is there too (up and down movement)...to keep people out:)..and as a second lock just in case the pin comes up in travel..

:sombrero:

[Willman]

Ah! good to know Will. ;) Out of curiosity, what's the distance between the tailgate and the area of gate contact on your trailer?


The swing gate is 47" long

From the tailgate with the swing gate open.. it is 50".....and 3.5" more intil you hit the front of my trailer...

Hope this helps...

;)

[02TahoeMD]

Well done! I may have to steal your lock idea and do that to my tire carrier. Kudos..... :beer: