AceFord04

I figured I would put together a build thread for my rear bumper I'm working on.

Materials Used:

• 1.75" DOM Round Tube 0.120" Wall Thickness
• 3/16" Steel Plate

Started out by removing the factory rear bumper and hitch.



This is what the frame rail ends look like. I plan on using the 3 holes on the frame end as well as the 4th hole on the side of the frame.




Made a template out of cardboard to get a rough idea of the boxed frame ends.




Got the boxed frame ends cut out and tac welded together.
Cutting the plates to make this took forever...I really need a plasma cutter.



The notch is what the main tube will mount to.

AceFord04

All welded up.
Bolts were welded from the inside.




4th hole drilled to mount to side of frame.




I wish I took pictures of the tube bending process, but we had our hands full trying to get it done.
Here it is welded in place. There are also two tubes welded to the backside for support.

AceFord04

Again wish I took more photos, but these are supports that go on the outside of the boxed frame ends to give support to the top tube.
Very tricky getting the angle right as well as notching the tube. (this was done with out a tube notcher, only a grinder with a cut off wheel and flap disc)




Here it is fitted in place.

AceFord04

All welded up and Installed on the truck.









Since the new bumper is higher on the ends I cut/dove tailed the fender to match.





Isn't completely finished yet. Still needs paint. I have backup lights I want to install as well as a permanent way of mounting the license plate and tag light.

I also plan on fabricating a receiver hitch in the center of the bumper.

Stay tuned for more!

chimmike

looks good man, I like it!

Nice fab work

Kkline

mustbeme

I think a combo of tube and boxing would look good. With all these plasma table guys, you can get pieces cut for nothing and create some good bumpers.
Here's a tip, hot glue gun is the bomb for making cardboard mock ups.