Login or register:
Login:
Password:
Register!


Imageserver Favorite:


Portfolio Galleries:
Animals
Architecture
Flowers
Landscape
People
Wildlife

Recent Subjects:
ebike
Box diagram
Boxes
Pool Automation
P


Search:


Resources:
Latest position from APRS
My public CVS server
My instance of AprsWorld
ImageServer

Friends:
Vanessa Park
Jon Sullivan
Chris Bell
Steve Kehlet
Mark Blair
Andy Chou


New Articles:

Hacktastic e-bike
Folded metal box
Raspberry Pi Home Automation
Farnsworth Fusor
Land Anchor
Turchickentato
Bowmaking
Custom Discovery Roof Rack
August, 2012 - Sierra Backpacking
July 22nd, 2012 - Hiking in Santa Barbara
July 15th, 2012 - Valley of Fire
May 5th, 2012 - Afton Canyon
April 28th, 2012 - Devils Playground
Alpine Tripod
Convict Creek Trail
January 2012 - Mustangs
January 3rd, 2012 - Heart Lake
August 7th, 2011 - Kelso Dunes
August 5th, 2011 - Lundy Canyon Hike
August 2011, Mammoth Archery
Birds in the garden
June 4th, 2011 - San Gorgonio
May 29th, 2011 - Sequoia National Forest
April 23rd, 2011 - Living Desert
April 2nd, 2011 - Death Valley
March 8th, 2011 - Mountain Palm Springs
February 13th, 2011 - Iron Smelt
Blacksmithing
November 13th, 2010 - Mojave
October, 2010 - Mammoth
Android
September, 2010 - Mammoth
September, 2010 - Duck Lake Trail Backpacking
Red
Iron bloom forging
August 28th, 2010 - Mt. San Jacinto
OSM Import: US Designated Wilderness
July 25th, 2010 - Mojave Mustangs
July 17th, 2010 - Mojave Exploration
Bloomery furnace iron smelting
Open Street Map: Mojave Project
June 13th, 2010 - Mojave
June 6th, 2010 - El Cajon Trails
Wolf Mountain Sanctuary
Carrizo Gorge
March 28th, 2010 - Salton Sea
March 21st, 2010 - South Main Divide
March 13th, 2010 - Anza Borrego Wildflowers
March 7th, 2010 - CSULB Japanese Garden
February 2010 - Mammoth
GeoRSS
AISlib
OpenStreetMap
Dakota and Asha Celebrate Christmas, 2009
November 21st, 2009 - Mojave Road
November 14th, 2009 - Anza Borrego
Exploring The East Mojave: The Afton Canyon Area
Broken flex plate
Remote Image Serving
Astro/night photography in Inyo National Forest
Wild Mustang Sightings
RSS
September 26th, 2009 - Night Photography In Frazier Park
Whiskey
Brandy
August 15th, 2009 - Catalina dive trip
Astrophotography
Sensornet
January 24th, 2009 - Mojave Exploration
July 2008 Mammoth Vacation
AIS
President Barack Obama!
Rachel Maddow
Big Geek
Barack Obama
April 12th, 2008 - Wildflowers and Landmarks
My Grandfather's Alfa Romeo Spider
March 8th, 2008 - Carrizo Plain
Bridge To Nowhere
High Availability
October 20th, 2007 - Big Bear Camping
October 22nd, 2007 - Fire
Scottish Highlands, Aug 7th, 2006
Scottish Highlands, Aug 6th, 2006
August 5th, 2007 - Duck Lake Trail
May 26th, 2007 - Kelso Dunes
Culloden Battlefield, Aug 5th, 2006
May 20th, 2006 - Irwindale Renaissance Faire
Edinburgh, Aug 4th, 2006
The Clifs of Moher, Aug 3rd, 2006
The Burren, Aug 2nd, 2006
Bunratty Castle, Aug 1st, 2006
May 5th, 2007 - Mojave
Truck Audio/Data Network
2007 - Master Bath Remodel
Centrum: Exit
The Ring of Kerry, Jul 31st, 2006
Nikon D200
Victory in 2006!
Blarney and Killarney, Jul 30th, 2006
Dublin and Cork, Jul 29th, 2006
Dublin, Jul 27th & 28th, 2006
Married!
What Can I Do?
April 30th, 2006 - Anza Borrego
New desktop: Intel 805 D
Macro Photography
Jan 7th and 14th, 2006 - Hiking
Whiting Ranch Hiking
Engaged!
Digital Photography with Linux
September 5th, 2005 - Living Desert
August 19th, 2005 - Mammoth
Hiking and Photography
July 30th, 2005 - Tucker Wildlife Sanctuary
Nikon D70
Death, Fright and Photography
Mmmmmm Eggs
MythTV
Inova T4
May 14th, 2005 - Red Rock
April 2nd, 2005 - Death Valley
Count Every Vote Act of 2005
Image Archiving
Linear Logic ScanGuage
Gentoo Linux
November 6, 2004 - Mojave
Super Tuesday, 2004
John Kerry
Kayaking
Irish Stew
ImageServer
Ireland, 2004
Canon A80 Camera
Jul 25, 2004 - Death Valley
Chronic Hiccups
May 4th, 2004
Landscaping - My Front Slope
Stump Pullin' Yeeee Haw!
Feb 22nd, 2004
Feb 16th, 2004
PostgreSQL Logfile Analysis
Spam
Mountains? Desert? Jan 30th, 2004
Jan 28th, 2004
Encryption
Ceiling Cargo Basket
Front Bumper Version 2
Asha
Exide Orbitals
Land Rover Valve Jobs
Spirits
The Matrix: Revolutions
Halloween 2003
Greg Davis CDL Linkage
Ouzo
Democracy
Mom's Turkey Gravy
Grandma's Guacamole
Top Nodes
Julian Pie Company
DeCSS
The KB1DIG 2-meter Halo Antenna
Incomming searches
Gardening is hard!
Aug 13th, 2003
SQL and Perl
Cancun 2003
Jul 9th, 2003
Aprs intelegence
Jun 17th, 2003
Some People's Comments
Dakota is a silly dog
The Matrix: Reloaded
Chris' Stage Bottle Harness
April 23rd, 2003
Cracked Radiator!
Vanessa
Black Wednesday
DVD Burning Under Linux
My Satellite Phone
Wind!
My Near-Death Experience
Laser Cannon Revival
Front Bumper, Version 2
SpamAssassin
The Critters
Dakota
Milton
KPC 3 Plus and HTX-252
My House
Moving, moving moving...
Mobile 1
Portola Hills
New new house
Suse Linux
Database images
In Truck Dr. Pepper
My Favorite Toilet
Kelso Dunes
Desert Trips
Ifulmuh
Late Thoughts: Dr. Pepper Cooler
265/75-R16 Tires on a DII
Linux
George W. Bush
Rants
Driving
Reservations
Horses Sep 14 2002
Sawdust Bellydancing 2002
Obsession
August 17th Yukon Dives
Less notifications
My Custom Front Bumper
Bracketless, Renamable Links
Discreet Winch
Welding
Jul 28 2002 Day Trip
My Firewall
Jedi Group, my T1 and money
A Bumperless Discovery!
My Custom Rear Bumper
Vanessa's 24th Birthday
Jun 30th Dive to Long Beach Canyon
PHP/PostgreSQL String Quoting
Tonsillectomy, Uvulaectomy and Turbinite Reduction
Searching functionality
240 Watt CO2 Laser Cannon
My Workspace
Dr. Pepper
The Tulsa Rib Company
The quality of hard disks these days
Email notification of articles
Email notification of comments
erikburrows.com source code
User Bios
User Preferences
Login feature
Renisance Faire Jun 9, 2002
Computers hate me, and it is mutual.
Star Wars Sucks!
Horses, Jun 1, 2002
Land Rover Mileage
Insomnia, Robin goes evil.
100 Watt Diode Laser Test Firing 1
Amateur Radio
The Matrix
2001: A Space Odyssey
TDI Deco Class
Horses, Apr 30, 2002
APRS
Movies
Blackbird
My Truck Batteries
My Truck
Vasquez Rocks
The Zope Bible
PSK31
Mojave Apr-12-2002
100 Watt Diode Laser
The New www.erikburrows.com
Hunter the Kitty
Horses
Geeks
Yukon May-13-2001
Computers
Ironage Jul-4-2001
Mojave Jan-27-2001
Mojave Apr-01-2001
Mojave Feb-10-2001
Ironage Feb-03-2001
SCUBA
Mojave Jun-09-2001
Programming Languages
Jedi Group
Matts Desert Pics
My Custom Rear Bumper   -   2002/07/10Viewed 142 times this month, last update: 2005/01/30


The rear bumper that came with My Truck is a silly thing. Big, plastic, heavy (for plastic) and low to the ground. My very first trip to the desert, (Ironage Feb-03-2001)I dragged it on the ground, and dislodged the thing.
So, I am building a new rear bumper. The base is a four-inch wide cold-rolled steel tube, bolted to the old mounting holes. I will be putting wrap-arround end caps on it, to make it look much like the original bumper. It will also get at least two more frame mounting points, and I will attach to it quarter-pannel sliders so I can drag the whole ass of my truck on a rock. (Or, more likely, sand and gravel.)
The first part of the project was making the main beam of the bumper. It is 4"x4" cold-rolled steel bar. I cut it to length, and drilled eight holes in it. Four 10mm holes for the bolts on the rear side, and four 1.5" holes opposite to get the socket in there.
Next was making and welding on the spacing plates. These plates have the same 10mm holes drilled in them, and are welded in place over the beam holes. These plates stand the beam 1/4" off the frame bumper brackets, which allow it to clear the body lip. They also act as giant washers, spreading out any pulling or torsional forces from the bumper to the bolt heads.
The bolts holding the bumper to the rear of the truck frame go from the inside rear of the main beam, through the spacer plates. That means that when in, the bolts must be accessed through the large holes in the front of the bumper. I dicided that I wanted these holes to be larger, and to be lined, so that if I drop the bolt, it isn't lost forever in the beam.
So, what I did was to widen the access holes in the front of the beam tube to allow me to weld in place four 1.5" ID pipes. I then ground these flush with the front surface of the beam. These are not structural, but simply keep me from losing bolts.
The ends of the bumper need to wrap arround the rear sides of the truck, and reach down to the bottom of the 'quarter panel'. I dicided to acomplish this by welding 4"x1/4" steel panels to the sides, two at 15 degres in-turn angle, and one at 30 degrees. These panels are welded together length-wise, and attached to the main beam by a weld across the front of the beam, and by two bridging brackets on the bottom and rear.
Once the caps were welded together and attached to the main beam, I trimed off all the extra material, giving it a smooth upward angle from the rear of the truck's quarter panel, and ground smooth all the external welds.
The entire assembly laid out before mounting.
The mounted bumper. I like it. It turned out 90% as well as I had hoped, which is far more than I expected. I still need to attach it to the truck frame in one or two more places, put a non-slip surface on the top, and paint it, but it's pretty much done! It weighs about 60 pounds, so the rear of the truck isn't visably lower, and I can lift it myself.
I was worried that when the side panels drag on somthing, the resulting twisting force on the bolt heads holding the bumper to the frame might be too much. So, I welded two 2"x2.25"x.5" tabs to the bottom of the main beam, which allow me to bolt the tabs directly onto the beefy trailer hitch. That way, if the bumper wants to twist, it's either pushing or pulling on those tabs, instead of trying to snap off bolt heads.
I dicided to forgo the quarter-panel sliders, since the rear corner of the bumper would hit ground first anyway. So I dicided to wrap-up this project. I sealed up all remaining holes (mostly where the caps met the beam) except for one 'drain hole', and painted the thing. Three coats of matt black rustolium, and I'm done. Once I got finished bolting it onto the truck, it was after dark, so final pics tomorrow. Can you belive I actually managed to strip a 12mm nut? Sigh... Oh well, there are five other bolts holding the thing on while I figure out how to get that one out.
Done! Done! All done! The thing is solid as a rock, and I think looks great! I can't wait to drag it on a rock.

Comments:
Matt Bell (2002-08-02): Wow! That looks great! You might think about getting it hot dip galvanized before you paint it to make it rust proof.

Erik (2002-08-04): Thanks Matt. Galvanization would probably be good, but I think that'd be overkill. The rustolium should do a pretty good job protecting the outside, and the drain-hole combined with the So. Cal. sun should keep the inside just fine too.

Mike Bullivant (2005-01-30): sun, whats that..i live in the Uk. You've done a great job on the bumper ..its given me some inspiration.

Erik (2005-01-30): Great! Good luck Mike.

Ali (2005-02-11): Looks good and a nice, simple approach. Here're some constructive critcims: unless you're going to be installing a set of 35"s, I'd be thinking of protecting that huge rear end! I know you're not concerned with departure angles but it only takes one rock to crush the rear quarter panel and ruin your day. You have a nice foudation to work off of. The rear wing will do a nice job keeping light stuff off the body work. If you put too much side ways force on them, they'll contact your body. Have you thought about integrating the hitch receiver into the bumper design? Again, these are constructive criticms only, no offense intended!

Erik (2005-02-11): Thanks Ali, I agree. The quarter panels are more protected than they were, but still not enough. My next rear bumper design will involve cutting back the quarter panels, as well as integrating the trailer hitch (and in so doing, raise it a few inches), as well as integrating more visable reverse lights. However, I'm in no rush. This bumper has served me well since it's first day on the job.

Ali (2005-02-11): Erik, if you get a chance, check out the rear bumper from Rockware.net. It's a very simple but effective design and one that removes the vulnerable part of your Q panel and provide upward support (when you come down on a rock). For some ideas, check out my rear bumper: http://photos.yahoo.com/alia176, click on Fabrication folder. Or just email me alia176atyahoo

Erik (2005-02-11): I like it! Awesome work! I have heard of the rockware bumpers too, they look good, so does the Greg Davis bumpers, as well as a few other company's. There's getting to be a number of choices for DII owners. Good for you for bringing the beas of of your cruiser!

cody (2008-05-17): just a thought.. if you seal the inside of the bumper enough,,you can put an air fitting in and out in it, fill it with air, keep some hose in the back of the suv, and in the event of a flat tire, boom! you have an air tank

Erik (2008-05-19): Cody, actually a lot of people do just that, and it works reasonably well. However, for a single tire, like a flat, I don't think using a pump is too painful, and when it really counts, like airing up all four tires from a 15psi sand trip, the bumper doesn't have enough air capacity. I prefer to use a tire-inflator adapter on a SCUBA tank, which is small, and since I already have the gear, inexpensive. A lot of other people use CO2 tanks, like the powertank.

Chris (2009-06-10): Where & how did you relocate your blinkers that were on the existing bumper?

Erik (2009-06-10): Chris,
I mounted white flood lights to the bumper to act as my reverse lights, and wired them in to the existing signal lamp wiring harness. I then wired the turn signal lamp wires into the old reverse light wires, and installed yellow-colored bulbs into the old reverse light sockets.

I like this arrangement much better: More powerful reverse lights, and more visible turn signals.

Rugby (2010-08-10): Rustolium makes a great brush on bedliner that i undercoated my truck bed with. I'm looking to buid a bumper and will coat with that.

Your Name:

To add a comment to this page:
1. enter your name...
Your comment:
2. Enter your comment
Anti-spam check:
5. Press "Post Comment" button.

Email me at erik@erikburrows.com if you hate the new anti-spam checker.

See also: Welding, A Bumperless Discovery!, My Custom Front Bumper, Driving, Discreet Winch, Some People's Comments

permalink

Email me!


Erik Griffin Burrows and ErikBurrows.com are not responsible for any damage or loss caused by viewing this site, or actions taken as a result of reading any part of this site. Articles and comments on this site should not be taken as legal, medical, scientific, engineering, botanical, dietary or any other kind of professional direction. This site is not affiliated with any business institution.

You get the idea. This site is just another big pile of misinformed, uneducated, unsolicited opinion, and should be judged as no more truthful or accurate as anything else on the internet.

Don't Panic!