Images in front_bumper

Images in front_bumper

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original-bumper-detail

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Cardboard mock-up 2012-04-02

The corner curves are the hardest part

Internal supports for hitch receiver

Cutting out the shape with an angle grinder

First cut made 2012-05-21

It actually goes faster than I expected

Frame for bending front plate

Offset 2x4s provide the leverage

Working slowly, the curve begins to take shape

The lines across the face show where each bend was made

Easy under-vehicle storage!

Initial line-up of steel to bumper - still needs a lot of work

The pushbar mounts made great holders while adjusting the curve of the steel

Getting closer...

Almost there...

Nice tight wrap around the sides

Huge difference in approach clearance to the tire

Cutting out the top bevel

Setting pattern for top of bumper

Half of the top is cut out, and bevel is finished

Pieces all cut out

Lots of clamps and hammering to get everything shaped

First pass welded on the outside

Finally starting to take shape

Shaving a little off the top

Bad fit - this curve needs changed

The front corners had to be split to get the right angle

Recutting the curves

Section cut out and replacement pieces ready to shape

It takes a lot of hammering to match an existing curve

A tease of the finished look

Pattern for fog lights

Cross pieces to mount bumper to frame

Raised pieces to go around mounting nubs on frame

Top mount with offsets to clear frame nubs

Top frame mount and bushings

Detail of mount with spacer

Clips to attach sides to fenders

Tow shackles 2012-08-15

Shackles, receiver, and license plate mounted

It finally looks like a functional bumper

Reciever pin mechanism

Inside of bumper

Latch for hitch pin 2012-08-20

Slot that the latch slides through

Latch assembled

Building the housings for the fog lights

Openings cut for changing the bulbs and draining water

Angles cut to match the curve of the bumper

Cans cut to size and ready to weld in place

Cutting out the opening

Ready for cleaning

Welded in place

First fog light polished

Center of underside bevel 2012-09-05

The recessed plate where the skid will mount

Leftover steel - perhaps enough to make the pushbar?

Rest of bevel pieces cut

Some shaping done on the first piece

Underside bevel in progress

Control rod for hitch pin

Some trimming needed

Detail of back side

Fender plastic trimmed up to new bumper

Very nearly complete