Custom Rear Bumper Started (need opinions on something) Pics Too!!!

[Boston Mangler]

Hey Guys

The rear bumper project has begun and took a weird but possibly good turn. Curious what you all think.

I had 2 custom mounting brackets made out of 3/4" plate (can you say overkill?) and the machinist making them goofed on one of the dimensions (kind of my fault the way i had the dimension diagram drawn). These were fairly expensive to have made, so we wanted to "Make Em Work"

Here is what we did:

The hole for the D-ring mount was drilled to 1 1/2" instead of 1". I know this is no big deal and there is still AMPLE amounts of meat there to support pulling the rig if needed (the plates are 3/4"!!!!). My problem was that the hole was way too big and the D-Ring was bouncing around like mad and making a racket. Looked kind of 1/2 assed too!

Anyway, the machinist and i designed these bushing out of some poly stock he had laying around the shop. At first i thought the idea of pulling such a heavy vehicle in this manner was a little hokey, but he assured me that the poly is plenty strong enough and now i am starting to think this might turn out to be a very good thing for a few reasons!

The bushings were machined for a very snug fit both into the hole of the 3/4" plate and for the pin of the d-ring.

The theory behind this idea (besides trying to make these work) was to eliminate the loud rattling and to protect the powdercoat.

Here is the link to my little writeup:

http://www.yankeetoys.org/mangler/80rearbumper.htm

Here are some pics. Please give me your opinions:

The bushings shown here are just made out of some plain white stock he had laying around and also have a large diameter "shelf" to them. If i decide i want to use this method in the final design, we are going to make a set out of black poly with a much smaller "shelf"

[Nullifier]

good idea but why not just leave the clevis out when not in use. It is a common theft item around here so we all just leave them off untill needed. no rattles or damage to powdercoat/paint.

[Boston Mangler]

good idea but why not just leave the clevis out when not in use. It is a common theft item around here so we all just leave them off untill needed. no rattles or damage to powdercoat/paint.

Yes, they will not be on the rig, unless i am on a trail or similar then i will have them on (its a pain fishing through all the gear to get them when you need em, usually comes at the worst time).

This will (in theory) protect the powdercoat when in use as well.

[IggyB]

Looks good.

Consider sanwiching the frame with another, thinner, piece of steel on the inside of the frame.

[Scenic WonderRunner]

How nice to be able to have a truck sitting in your driveway to be able to work on.....Kevin!

[Boston Mangler]

Looks good.

Consider sanwiching the frame with another, thinner, piece of steel on the inside of the frame.

Oh, for sure!

Already have the piece cut actually, just need to drill it!

Thanks

[calamaridog]

Sometimes the greatest innovations are caused by overzealous machinists

Black would look better

[Scott Brady]

I really like that idea! reduced noise and a pretty trick look

[blupaddler]

Kevin

Looks good!



Just thinking out loud here...but you might want to start consider swaping out your 863 rear springs for some 864's. With the rear bumper, rack, and the aux. tank...you're going to be really loaded down. In fact pretty much the only way you'll sit level with a full aux. tank and a fully loaded 80 will be with the 864's.

[60seriesguy]

Don't forget the back loaded up for the trips to Baja!