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Unread 03-15-2013, 10:23 PM   #1921
WSS
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Started my bumper today. I learned two things:

1) Shipping cost of a GPF bumper would not have been so bad
2) Eddie does not charge enough LOL

Put a bunch more detail in my build thread

WSS

dscn8343.jpg   dscn8346.jpg   dscn8354.jpg   dscn8372.jpg  
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Unread 03-16-2013, 09:56 AM   #1922
jstman
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Quote:
Originally Posted by WSS
Started my bumper today. I learned two things:

1) Shipping cost of a GPF bumper would not have been so bad
2) Eddie does not charge enough LOL

Put a bunch more detail in my build thread

WSS
That's FUNNY!!!!
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Unread 03-17-2013, 01:06 PM   #1923
WSS
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Originally Posted by jstman View Post
That's FUNNY!!!!
Somewere in this thread I read he is doing one in about four hours. Cool, I ought to be able to knock one out in 10-12 right? No way! I have that in it now and not even close. I bet I get 40hrs in it before it gets painted. The last pic shows the empty wire reel, typical weekend hurdle LOL

Here is what I managed today:
photo398.jpg   photo399.jpg   photo401.jpg   photo404.jpg   photo405.jpg  

photo402.jpg  
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Unread 03-17-2013, 05:02 PM   #1924
BESRK
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Nice work!! I used to cut all my bumper blanks by hand.. the past few years, I've been doing them on the plasma table like you did. I do 2 at a time, flip/swap them and cut again. I can cut 10-12 per hour or so without too much fuss. However, last week I got sidetracked talking to a buddy and cut 2 bumpers upside down on one side. Wasted 2 good blanks... oh well.

Did you pound those ends into submission? I see the torch laying there.. At any rate, nice work on that.

I think my first couple bumpers took me about 12hrs to complete. Between yesterday and today, I did 2 complete tire carrier bumpers start to finish... and a front bumper with winch plate/winch hoop/receiver. Also cut a half dozen winch plates, 50 bumper mounting plates (1/2" thick), and a bunch of shooting targets. Okay.. I cheated.. the plasma table cut all the stuff... but I did push the "start button"...
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Unread 03-17-2013, 08:01 PM   #1925
WSS
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I have a few of those "lack of focus trophys" laying around LOL.

Do you like the new (duramax) torch? I am still learning it. I found I can up all the nozzles at least one jump like from 60 amp to 85 amp and get better quality out of it. But the volts seem a bit more sensitive.

I did pound them, the first bend was just a warm of the torch and a c clamp, the second, sharper bend needed more heating and a bigger hammer. If I was to build another bumper, I would cut a little closer to the web and leave less of the curved part of the tube corner. I think it would bend straighter and not cave in the center so much. I was able to get it pretty flat but it took more work than necessary.
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Unread 03-18-2013, 10:34 AM   #1926
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Quote:
Originally Posted by WSS
I have a few of those "lack of focus trophys" laying around LOL.

Do you like the new (duramax) torch? I am still learning it. I found I can up all the nozzles at least one jump like from 60 amp to 85 amp and get better quality out of it. But the volts seem a bit more sensitive.

I did pound them, the first bend was just a warm of the torch and a c clamp, the second, sharper bend needed more heating and a bigger hammer. If I was to build another bumper, I would cut a little closer to the web and leave less of the curved part of the tube corner. I think it would bend straighter and not cave in the center so much. I was able to get it pretty flat but it took more work than necessary.
That is so much easier than how I build mine. Haha I cut out the wedges with a grinder then just beat it with a hammer till it is in place. I don't have any fancy torches. And the the holes I just cut out a square rectangle and then weld it in.
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[URL="http://groups.jeepforum.com/built-not-bought/"][COLOR="Black"]Built Not Bought #640[/COLOR][/URL][/FONT][/SIZE][/COLOR][/CENTER][/COLOR]

1976ish cj5 304 t18 d20 2.5" lift

some year YJ custom frame HP D60 14 bolt 4 linked front rear FI 350 700r4 NP231c

2009 JK 4 door 2.5" lift 35" tires custom bumpers mile marker 9500# winch
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Unread 03-18-2013, 06:43 PM   #1927
BESRK
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For my own bumpers, I just cut that whole end off. I then cut rows and rows of 1.88" wide strips that get welded/hammered into place to form the ends. That allows me to cut my bumper blanks at 58". On a typical 24ft stick, I get 4 full size (58") bumpers and one 54" bumper. With 48" front bumpers, I get 6 bumpers per stick.

I do like the Duramax torch! I'm getting better consumable life and cut quality is better than the original PM1250 consumables I was using. For the most part, I just cut at the recommended 45 and 65 amp settings. I haven't even bothered to crank it up to 80amps for anything.. including 3/4".

Here's some 3/8" I cut for a customer. He was getting these brackets laser cut but wanted to see if he could get a better price without losing too much quality..

Original laser cut example he sent me.. standing next to my plasma cut "imposter"


Again.. original laser cut example laying next to my plasma cut version. The "imposter" was done by taking a digital pic of the original, importing it into CAD.. and scaling it to size. I did drill the small hole whereas the laser version can cut a small hole with no taper.
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'80 CJ5 w/AMC360, T176, D44 w/Detroit 4.56, RE 4" YJ lift and 35s..

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Lower 2

Guardrail

Down Schoolbus

Slickrock Tellico

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Crozet

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Unread 03-18-2013, 09:47 PM   #1928
WSS
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Quote:
Originally Posted by 8pitcher View Post
That is so much easier than how I build mine. Haha I cut out the wedges with a grinder then just beat it with a hammer till it is in place. I don't have any fancy torches. And the the holes I just cut out a square rectangle and then weld it in.

You cold formed it? What an animal! The irony is it will probably outlast mine. I am going to have to do a mild stress relief or drop it in the press. I managed a nice 1/4" bend in it. Went slow but lots of weld.

Eddie, whats the rule on pivot/spindle location? I drilled the holes too far out (away) from the frame mount I think. I pugged them and re-drilled about 2.5" from the mount in hopes it will minimize flex. Should it be closer to the mount? The problem is I lined the shackle mounts up with the mounts for strength.

WSS
photo410.jpg   photo415.jpg   photo418.jpg  
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Unread 03-18-2013, 10:02 PM   #1929
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Just noticed the pics in the post, That is some clean cutting. The imposter is hard to find. What is the tolerance on the hole? You are getting some smooth motion out of your machine. The big guys would have a hard time getting that quality.
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Unread 03-19-2013, 05:34 AM   #1930
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Not sure what his required torlerance was.. basically able to slide a 3/8" bolt thru the small hole.. and 2.25" on the larger hole. When folks ask me how accurate my plasma table is, I tell them.. "Tape measure accurate"..


For the spindle and latch locations. The important thing is to make sure they're far enough outboard to not interfere with the tail gate opening.

On my 58" bumpers, my spindle hole is about 7.25" from the end of the bumper.
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'80 CJ5 w/AMC360, T176, D44 w/Detroit 4.56, RE 4" YJ lift and 35s..

Ground Pounder Fab


Lower 2

Guardrail

Down Schoolbus

Slickrock Tellico

Save

Crozet

More Crozet
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Unread 03-19-2013, 06:04 PM   #1931
WSS
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Quote:
Originally Posted by BESRK View Post
Not sure what his required torlerance was.. basically able to slide a 3/8" bolt thru the small hole.. and 2.25" on the larger hole. When folks ask me how accurate my plasma table is, I tell them.. "Tape measure accurate"..


For the spindle and latch locations. The important thing is to make sure they're far enough outboard to not interfere with the tail gate opening.

On my 58" bumpers, my spindle hole is about 7.25" from the end of the bumper.
Cool, I do not have a gate, so I should be OK, I know it may seem odd to have a swing out but I do have other stuff tucked behind it and there is a small storage spot behind the back seat.

One request with sugar on top:
May I shamelessly copy your shackle mount/tow bar adapter?

WSS
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Unread 03-19-2013, 07:55 PM   #1932
BESRK
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How's the sayin go?.. "Copying is the highest form of flattery" or "mancrush".. or "bromance" or something like that.

If you like, hit me up with your email, and I should be able to send you the DXF..
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'80 CJ5 w/AMC360, T176, D44 w/Detroit 4.56, RE 4" YJ lift and 35s..

Ground Pounder Fab


Lower 2

Guardrail

Down Schoolbus

Slickrock Tellico

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Crozet

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Unread 03-19-2013, 08:51 PM   #1933
WSS
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Dude, that is great. I would joke and ask if you want to cut it for me too, but I would not have the chance to "bromance" you LOL.

Thanks REALLY!
I'll send you a PM.

WSS

PS, my humble dxf collection is at your disposal.
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Unread 03-21-2013, 10:33 PM   #1934
WSS
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Big thanks BESRK!!

File was great and they cut flawless. Thanks! One step closer to the desert.

First pic is as cut still wet off the table, fit like a glove. There is a lot of weld on those little guys.



Plus, got a few hours in on the bumper. Yaaa!

WSS
photo435.jpg   photo437.jpg   photo439.jpg  
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Unread 03-22-2013, 09:26 PM   #1935
WSS
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Well, the bumper is about as finished as it's going to get. I am not real happy with top rack and can holders but it will work. I can go back and re-do it next winter if it does not hold up this season. I used the old warrior/rubicon rack that was on it when I bought the Jeep, so it is the only thing I did not fab myself. I kinda "made" it work.

Next is "finish" grinding then paint. She will be ready for the trails!

All the parts that I used from AtoZ fab's bumper builder kit worked great. I did the mega spindle and it sets up tight. A big thanks to all the input and pics here in this thread! The bumper resembles GPF's because it works! Hard to invent a new wheel.
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