Project Bumper Build Help

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I have been milling around on here for a little while and am still fairly new. I am wanting to make a big steel bumper for my 97' Dodge pickup. I am planning on using a 48" piece of 2" x 6" C-channel and 3/16" plate. I know there are a few guys on here that have built custom bumpers and was wanting some input. I have drawn up a design for mounting it to the bumper mounts and was looking for some helpful advice. This is my idea and was wondering what everyone thinks.
Reply:I fabricated a set of front and back bumpers for my duramax. Everything for the back bumper was laid out as it were all "unfolded" on a 4x8 sheet of material. The front one was made in 3 sections as the whole front is 1/4" and the other two sections were 3/16". But all those 3 sections were also laid out like that. Garuntees it will be perfect symetrical. These may not be the route you want to go but may give you some ideas. Attached Images
Reply:more. Attached Images
Reply:Wow thats nice!! Did you use truck bed coat for the paint?Ya gotta spend money to make money!
Reply:I have seen your bumpers on here, and they are really nice. Your truck is one of the nicest iver ever seen. However, this is my first bumper build and i want to make it pretty simple. Also i dont have acess to some of the equipment yall have. I have a 220 amp lincoln stick welder, a millermatic 251 mig and a lincoln 110v fluxcore welder. Im thinking i will tack all the sheet metal up with the fluxcore and then weld with the stick. Im planning on cutting the sheet metal with a cutoff wheel because i do not have a plasma cutter and am afraid a torch will be too rough. Any ideas on the structural part?
Reply:opps nevermind this postYa gotta spend money to make money!
Reply:Originally Posted by welderShaneopps nevermind this post
Reply:Hey man, we've got the same truck. So, when you get that bumper built, I want to see it.If it turns out awesome, I'd be willing to make that long journey 10 minutes north on 169 to see it in person.
Reply:Why would you use flux core and stick when you've got a 251?My name's not Jim....
Reply:I am a senior in high school and am in FFA. The fluxcore is mine and i will be doing most of the build myself at home. The miller and stick welder are at my school shop. Im fairly new to welding and i figured that stick would be the way to go. But i posted for advice so this is a good question. The miller is hooked up to 75/25 argon/oxygen. We have 6010, 6011, 7018 all 1/8". What should i use for all the final welds?
Reply:that 75/25 is probably argon/co2Dynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:Originally Posted by Broccoli1I imagine he's speaking to the person that Posted pictures of Bumpers
Reply:The MM251 would be my pick to use for this project, but whatever you feel comfortable with and have the most access too.  As far as the torch, just like welding, the proper heat and travel speed will produce pretty smooth cuts, just get your arms and body braced. Besides the more practice you get the better your cuts will be. Using a cut off wheel getts old on thick stuff pretty quick, not to mention you'll go threw a lot of discs. Good luck and keep us posted!My toys:Mobile Set Up    Miller Bobcat 225NT    Oxy Acetylene cutting set up    Red D Arc 12VS wire feeder    Spoolmate 3035 spoolgun     Scratch Start TIG DCMiller Elite auto hood
Reply:Originally Posted by arcrayUsing a cut off wheel getts old on thick stuff pretty quick, not to mention you'll go threw a lot of discs. Good luck and keep us posted!
Reply:Not sure if you have been going down this trail already, but you also have the opportunity to add to the conventional bumper design for your own purposes. For example, a small tool box/chain box. Light mounts. Winch plate. etc.I like gadgetry!
Reply:I plan on cutting out holes two holes in the front to house 2 6" off road lights and also a blinker/parking light running diaganolly on the corners.
Reply:Started cutting and welding this weekend.
Reply:I use cut off wheels and sawzall for my cuts.Lol, I'm honestly just better with the saw.Just cut it, and grind it to the exact angle But then again, Im not into Major welding like some of you guys!Going to make a bumper soon though!Last edited by 1_black_z28; 12-16-2010 at 01:12 PM.Lincoln 125HD, yep I'm a big spender.
Reply:Havent posted pics lately, but its gettin close to finished.
Reply:A few more. 3rd picture is my fancy paint booth.  Attached Images
Reply:Finished and sprayed with Raptor truck bed liner. I was first going to use automotive paint but we had some extra bed liner from my dads ranger so i went ahead and used it. Boy am i glad i did. It looks gret and it also covers up some of the small defects like high spots in the welds and stuff. I really like the finish and ill post some pictures of it on the truck and with lights installed tomorrow.
Reply:Looking good so far. I have built a few dodge bumpers and have to say 1/4 and 3/1/6 is the way to go. Keep the weight down and use gussets. Pressure_Welder, is that similar to a fab four bumper design? haha  Im doing something similar as well for my truck.
Reply:Intimidator...I know you have painted and it looks really nice, but I would put some beefier mounting bracket to the frame incase you do call that beast into service. Maybe those factory ones will be fine, just my opinion.I had a bumper I built and bent it upward and knocked out my front lights... defeated the purpose of heavy duty bumper even though I had the winch going at the time and had taken off a support that I did not think I needed.Looks good.
Reply:If i was going to do it again, I would make the mounts sturdier. But this truck is only 2wd and a 1/2 ton so I dont plan on putting a whole lot of stress on it.
Reply:And finished. I totally forgot that i was going to put guards around the lights before i painted it. But i think a can figure a way to bolt them on.good job. A little boxy for my taste, and a little unproportional to the truck. But good job nonetheless
Reply:Originally Posted by Pressure_Weldergood job. A little boxy for my taste, and a little unproportional to the truck. But good job nonetheless
Reply:Nice work. Keep on thinking and building things for yourself.Brett B & B Fabrication and Welding Inc.Spalding, MI.
Reply:Put a bar on that thing it will look like an apartment balcony A little big for my taste, but good work.You have to learn the rules of the game. And then you have to play better than anyone else. Albert Einstein
Reply:Nicely done!
Reply:Great job on the bumper. I would hate to be on the business side of that baby!Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Originally Posted by jreynoldswelding  Put a bar on that thing it will look like an apartment balcony A little big for my taste, but good work.