Anyone build a truck bumper before?

[g352nv]

Well my guy has the flu and hes been laid up. Im really wanting to get this going! I may just do what I can with a cut off wheel and see how it goes.

[g352nv]

Cut it out with a angle grinder, took 12 cut off wheels lol. Looks like it will weigh less than my OEM bumper, 56lbs so far.

[Charlie206]

That’s some seriously good cutting with a grinder. Great job.

[JerryT]

Do you plan on Just butt welding it all together ??

[g352nv]

Do you plan on Just butt welding it all together ??

Thats the plan, Ill take it all together first and then weld it all up.
Im still waiting on the light bars so Ill have to cut the center out later. I hope to get started tacking everything this weekend if I get some time. Any welding tips?

[g352nv]

That’s some seriously good cutting with a grinder. Great job.

Thank you.

[TRCM]

Thats the plan, Ill take it all together first and then weld it all up.
Im still waiting on the light bars so Ill have to cut the center out later. I hope to get started tacking everything this weekend if I get some time. Any welding tips?

Tack it however you need to, but I'd weld the inside of the joints (inside of bumper) to make sure you get a good weld for the strength you need, then when all the inside/strength welding is done, weld the outside up and dress it for cosmetics.

If you weld the outside for strength, and then try to make it pretty, you may hurt the weld.

I'd also look into some sort of jig fixture or weld table to hold it while welding and to keep it from warping. It doesn't take much heat in the wrong place to tweak it and give you all kinds of headaches.


I was looking at getting 2 of the 24 x 24 models below and putting them together...lots of flexibility that way, and a little cheaper than other tables.
I do have some tables here I have made that I could convert to welding tables like that fairly easily, but not so sure they are flat enough.

https://weldtables.com/collections/fabblocks

[g352nv]

Tack it however you need to, but I'd weld the inside of the joints (inside of bumper) to make sure you get a good weld for the strength you need, then when all the inside/strength welding is done, weld the outside up and dress it for cosmetics.

If you weld the outside for strength, and then try to make it pretty, you may hurt the weld.

I'd also look into some sort of jig fixture or weld table to hold it while welding and to keep it from warping. It doesn't take much heat in the wrong place to tweak it and give you all kinds of headaches.


I was looking at getting 2 of the 24 x 24 models below and putting them together...lots of flexibility that way, and a little cheaper than other tables.
I do have some tables here I have made that I could convert to welding tables like that fairly easily, but not so sure they are flat enough.

https://weldtables.com/collections/fabblocks

Again thanks for the advice. Ill do that for sure.
Yeah being a autobody paint guy Ive had some fun times with sheet metal lol. It will be fun welding something thicker hahaha.

[bullet20vee]

Thats the plan, Ill take it all together first and then weld it all up.
Im still waiting on the light bars so Ill have to cut the center out later. I hope to get started tacking everything this weekend if I get some time. Any welding tips?

Stitch weld 2-3 inches on one end, then move to the other and do the same. Don't let too much heat build up in one area or it will draw. That will help it stay straight, tkae your time and let the parts cool before welding again in the same area.

[TRCM]

Stitch weld 2-3 inches on one end, then move to the other and do the same. Don't let too much heat build up in one area or it will draw. That will help it stay straight, tkae your time and let the parts cool before welding again in the same area.

When you do this, try and do the 2nd stitches on the opposite side too if possible. Sometimes, like in the case of this bumper, it probably won't be doable.

When I was teaching myself to weld, I was welding 2 - 5' long pieces of 2 x 2 tubing to each other to form a 2 x 4. I'd weld abut 3-4" on one side and one end.....it was amazing at how much that heat bent those tubes......so for the next time, I welded the same 3-4" on the other end, opposite side, and low & behold it straightened itself back up.

It was a learning experience seeing how as in direction in relation to where I was welding, and how much the heat warped the metal. I used what I saw to keep the metal from warping, and somehow, managed to build a 5' x 5' x 4' storage cube for lack of a better term, with 2 x 2 tubing for the outside, and 1.5 x 1.5 tubing for the slats across it. Every single side is straight, and every corner is 90 deg, but if you'd have seen it while I was welding, you'd swear I had a scrap heap I was just playing on.

Also did quite a few 'injection' joints while playing with my plasma cutter as well.....'injection' as in cutting a 1.5 x 1.5 hole thru a 2 x 2 tube to insert the end of the 1/5 x 1/5 tubing into and be able to weld it to both sides of the 2 x 2. not sure what that joint is really called......

[Wild Heethen]

Sure I cant see paying 2k for a bumper, do I have the money? Yeah, but I also like to challenge myself. I know its been a while but I have a few restos on here that Ive done. I owned a bodyshop, Ive built MANY toys. To do something yourself is something that feels good! 150.00 and my time while the lakes are frozen solid is something to do. You may be right in the end! But I love a challenge!
If I told you I was going to make a custom console for a Basscat what would you say? If I told you I was going to paint real flames on a boat what would you say?

Give 'er Hell man. I always respect a man that ain't afraid to do it himself. Will it look 'factory'? Probably not. But, I bet it'll be stout and you'll have the pride of saying---I built that.

[g352nv]

Give 'er Hell man. I always respect a man that ain't afraid to do it himself. Will it look 'factory'? Probably not. But, I bet it'll be stout and you'll have the pride of saying---I built that.

Thanks!
Nawi don't want it to look factory. It's looking good though. I got most of it tacked in place last night. I'll try and do some more tonight.
Ordered my button head Allen's today along with paint supplies. Oh and my LED lights came in finally.
Can't wait to get it all welded up and cut out the openings for the lights.

Thanks for all the tips guys.

[Axkiker]

Paint wise what are you looking to use. Reason I ask is because the bumper will take a lot of road abuse from rocks etc. It doesnt take much to chip cheap paint. Heck it doesnt take much to chip expensive paint.

If you are going to paint remember to use a HIGH QUALITY etching primer and follow with all mfgs recommended steps. I also advise to use all products from the same mfg if possible.

You might also consider a bedliner material as you can get them in about any color now a days.

Makes me want to build one. My grill and bumper are chrome though so I dont know how it would look with a chrome grill and painted or coated bumber.

[TMG]

That's a lot of cutting with a wheel
Looking forward to seeing it finished

[g352nv]

Paint wise what are you looking to use. Reason I ask is because the bumper will take a lot of road abuse from rocks etc. It doesnt take much to chip cheap paint. Heck it doesnt take much to chip expensive paint.

If you are going to paint remember to use a HIGH QUALITY etching primer and follow with all mfgs recommended steps. I also advise to use all products from the same mfg if possible.

You might also consider a bedliner material as you can get them in about any color now a days.

Makes me want to build one. My grill and bumper are chrome though so I dont know how it would look with a chrome grill and painted or coated bumber.

It will be automotive, Im PPG certified so I can hold my own when it comes to painting. I was going to do bedliner but I wont be happy with it and I want it color matched.

[g352nv]

That's a lot of cutting with a wheel
Looking forward to seeing it finished

Yeah it was! Took me about two hours lol.

[mgrice1981]

You are a fab master. I love seeing your builds. I'm guessing by most of these comments that people haven't seen your work.

Keep up the great work, and keep updating. I'm anxiously awaiting the finished product.

[g352nv]

You are a fab master. I love seeing your builds. I'm guessing by most of these comments that people haven't seen your work.

Keep up the great work, and keep updating. I'm anxiously awaiting the finished product.

I dunno about all that but thank haha.
Well no updates this weekend. Turned on the welder and got three welds done before I ran out of gas ugh. Welding shop isn't open until Monday. Sux.

[Axkiker]

I dunno about all that but thank haha.
Well no updates this weekend. Turned on the welder and got three welds done before I ran out of gas ugh. Welding shop isn't open until Monday. Sux.

Ohhh man you gotta get you a spare bottle... or 3. Best welding purchase I made besides the welder was spare bottles. Hunt craigslist and yard sales. You will eventually come up with some.

[g352nv]

Ohhh man you gotta get you a spare bottle... or 3. Best welding purchase I made besides the welder was spare bottles. Hunt craigslist and yard sales. You will eventually come up with some.

Pure truth! I went through the new bottle already but I'm almost done welding. Starting and stopping is really using the gas!