Custom Bumper Project

[Ldub]

I will weld this weekend, under the ends of the top cross bar I will weld some 2" angle iron as supports between the two bars right above the frame rail mounts.

May I suggest using round stock (tubing), rather than angle iron, for a finished product that has more visual appeal?

[Marlin]

Here is where I am now. I have the top tube welded on and the 3/8" thick angle irons at the outside. Now I can attach the front plate, once I get it bent. Ldub, I used the angle irons cause they were stronger, and it won't be visible once complete.
The driving lights fit perfect in between the tubes, should be done next weekend I hope, gotta add a few gussets, paint a few more coats, and voila, I will be done.

It is being painted right now, so I will post the final pics hopefully next weekend.

[Marlin]

Its getting there, I told ya I was going for the road armor look, and it is quickly heading in that direction. I should be able to finish the other side tomorrow, get it painted and mounted by say Fri, and wire up the lights sat, add some gussets and I will be done!!! Not sure how to fill in the gap, but it isn't near as big anymore. I am cutting the bottom rail tubing to a 45 degree angle and capping it. Then I just need to figure out how to mount my new skid plate, and all will be complete.
It is not as sleek as Orion's, but I said form the beginning I wanted the road armor look.

[nfpgasmask]

So you are just going to leave the front end and the area around the grill and lights all open like that????

Bart

[Marlin]

So you are just going to leave the front end and the area around the grill and lights all open like that????

Bart

I dunno yet, working on that, I may cut a sheet metal outline to fill in the holes...but at least admit that the actual bumper is heading in the direction that I said I was going to do!

http://www.roadarmor.com/site/ford/08-plus-sd.php

[Triathlete]

Looking MUCH better! Shouldn't be to hard to fill that top section. Use card board and bend it and cut it to make a templet. Then you can use a little thinner gauge steel. Cut it and bend it using the cardboard templet, a little more welding and presto!

[Ldub]

Looking MUCH better! Shouldn't be to hard to fill that top section. Use card board and bend it and cut it to make a templet. Then you can use a little thinner gauge steel. Cut it and bend it using the cardboard templet, a little more welding and presto!

Hell YEAH!...

Make it segmented, so it looks like scales (think rough fish)...or the Batmobile armor!