Offroad Bumper Build

[MadMax11]

There are a few reasons why I have decided that my stock bumper is no longer useful, and why a custom one would be:

1. Lower bumper lip scoops up gobs of mud and junk. And simply cutting it off does not look good on a GC imo.
2. Radiator support could use some reinforcement + skidplate mounting tabs.
3. No protection to the front sides of the car (slide into a few mounds of snow in the winter and you'll figure this out)
4. Foglight mounting locations are annoying, even with modifications (ease of access, protection, and appearance)
5. Overall appearance.

So I'm working on a solution.


Step 1: Strip it down
http://s205.photobucket.com/albums/bb37/maxgreenie11/Suby/1.jpg

Step 2: Cut it up (and tack on a tube for DDing to work :eek:)
http://s205.photobucket.com/albums/bb37/maxgreenie11/Suby/2.jpg

Step 3: Use an angle grinder + welding buddy
http://s205.photobucket.com/albums/bb37/maxgreenie11/Suby/3.jpg

Step 4: Wait until buddy gets back from vacation.. which is today!

So after some :cheers: we'll get back to it and see what we come up with.

[MadMax11]

Time for some more welding!
http://i205.photobucket.com/albums/bb37/maxgreenie11/Suby/3-1.jpg


Aaand check fitment again..
http://i205.photobucket.com/albums/bb37/maxgreenie11/Suby/4.jpg



Next step, internal bracing + foglights!

[90legacywagon]

looks awsome man good job cant wait to see it all together and back together love the front that looks like a stinger type bumper

[tyler_S18]

i like it! very DI! if it were me i would go for covering the side triangles with sheet metal and make some kinda grill to cover the rad but all thats just for looks and some minor twig protection lol! :thumbsup:

[MadMax11]

i like it! very DI! if it were me i would go for covering the side triangles with sheet metal and make some kinda grill to cover the rad but all thats just for looks and some minor twig protection lol! :thumbsup:

That's exactly the plan. Thanks for the great feedback so far guys!

Got the foglight tabs on last night! Too dark to see much though..
http://i205.photobucket.com/albums/bb37/maxgreenie11/Suby/2011-08-28223809.jpg

[Aut-Lin_37]

Wow that is just awesome! I'm planning on doing something similar with my '93 Impreza. Right now I just have the bottom of the bumper cut off. Keep up the good work :thumbsup:

[Dan McGinn]

Looks burly and badass, very AK! What material are you using?

[MadMax11]

Looks burly and badass, very AK! What material are you using?

The main hoop is 1" sch 40 steel piping, and the rest is 0.75" sch 40 steel.


And now, updates! One picture should say it all..
http://i205.photobucket.com/albums/bb37/maxgreenie11/2011-09-01141421.jpg

[Bacana_Innovative_Equip.]

so gnarly

[MadMax11]

The main hoop is 1" sch 40 steel piping, and the rest is 0.75" sch 40 steel.


For those tubing freaks, the equivalent tubing sizes would be 1.315" diameter with 0.133" thickness for the main hoop, and 1.05" diameter with 0.113" thickness for the rest.
My initial plan was to use standard 1.5" by 0.120" tubing for the main hoop, and 1" by 0.120" tubing for the rest. Then I found some scrap piping at a fat discount, so I went with that. The strength should be more than sufficient for beating it around offroad.

[MadMax11]

Aaand this is why a custom bumper is a good idea..

http://i205.photobucket.com/albums/bb37/maxgreenie11/Suby/car.jpg


It took 5 or 6 hard yanks with a tow chain to pull the bumper back out.
It took 1 soft yank to pull the radiator support nearly too far out.

Give that some thought.

[Bacana_Innovative_Equip.]

what'd you do?

[MadMax11]

what'd you do?

Slid off the road doing about 35 into a fallen tree. Rough night.

But I was able to back off and drive away.

[winski357]

badass

[Soupastud]

looks great

[MadMax11]

Did some more work the other day. Gussets + drilling + UHMW (3/8").

http://i205.photobucket.com/albums/bb37/maxgreenie11/Suby/DSC_0080.jpg

[1999_SilverStreak]

Thats a cool bumper.