New front bumper for the Rover

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Unfortunatly I can only post 5 images per post, and my full post over on my favorite Land Rover forums has something like 100 images and still growing, so this will be the "condensed" version.Basicly nobody made a bumper that fit my qualifications1)strong2)light3)sexy looking4)NOT $1200-2400So I built my ownWinch cradle mocked upGetting a little more beef into the mounting systemAnd now you see where this is going, the winch cradle is .250" plate, all the tubing is 1.5"OD .120" wall DOM.Main blade, bent and tacked in placeLower bar getting a tast-fit
Reply:Nothed and in place ready for tackingCouldn't resist having a look at what the final product will look likeThat's how far it sticks outRecovery point mountsThen ends on the bumper
Reply:main blade cut down to sizeSleeved at the joint, that gets a bead plus plug welds at various points all the way aroundEnd caps are onAnd it's the only level thing on the truckSide supports in place and tacked
Reply:light bar in placethe design/mock-up phase is completeNow we weldNOTE, kids, don't follow my example, you really sould weld in long sleeves, long pants ect. I am NOT a role model
Reply:Here's what you all want to see.Most welds were done at 175 amps (most my machine will put out) Everything was mig. C25 gas, .030" wire, ect. ect. All the plate was beveled and had 2 passes, the tubing was beveled and done in a single pass.It's sitting in the garage right now, letting the paint dry, but I should be able to get it installed tomarrow, then I just need another pair of Hella Rally 4000s (Anybody selling some?) and I'll be set.Thank's for looking
Reply:That is one rugged looking bumper you made there Max!
Reply:Sweet!Personally, I think it's way more rewarding in the end to build it yourself than too buy it! On a side note, I remember doing two 6" (ish) welds with .045 hardwire in spray once (we were fitting, and the lugs got welded before the rest did!) wearing a sleeveless shirt, and ended up being "sun"-burned for a week!a side-side note, Nice sticker!  I had one once on my last helmet that read "Don't p*ss me off, I'm running out of places to hide the bodies!"  ...sadly I lost it when I spiked said helmet off a wall and the thing exploded...DOH!Last edited by mb_welder; 07-04-2007 at 05:41 AM.
Reply:Very nice MAX! How big is the winch - 8k? I just bought a 6k for my truck. When my front bumper rusts out from the NY winters, I'll be building my own. Excellent set of photos!John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Nice job...I used to have hair that long..But with all the heavy machinery around Me everyday.. BZZZZZZZZZZZZZZZZZZZZ...All gone now.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Thank's for the compliments guys, It should be ready for install this afternoon, can't hardy wait. I've allready had a few guys ask me to build them bumpers like it, and they didn't balk at my $1900 quote, so I'm stoked, there's about $170 in materials, $40 in consumables and 20-25 hours in it, so if I can crank out a few it should be a nice little chunck of change, especially since welding is currently just a hobby.mb_welder- I used to get sun-burned from mig when I was spending 1-2 hours burning wire everyday, but not too badly. Now I seem to be able to go nearly forever without getting a sun-burn.Some relator sent out the "Rustin in Tustin" stickers in a mailer, so on the helmet it went.MicroZone-It's a Superwinch 9k, and I just got my Amsteel Blue synth winch line, that stuff is so nice Zap- it's a trade-off, you get to use all that cool/heavy machinery so you don't get long hair. That drill-press in the only "heavy machinery" I have, so I get to keep my hair.
Reply:Zap- it's a trade-off, you get to use all that cool/heavy machinery so you don't get long hair. That drill-press in the only "heavy machinery" I have, so I get to keep my hair
Reply:Great photo layout of the whole assembly. Nice design on the bumper!Latest Toys Miller 180 Mig and Elite Mask!!Wright Welder 225ACShop OutFitters 20/20 Bending SystemHypertherm 380 Plasma30 Years of Sparking (Electrical & Welding)
Reply:I like the work.  IMO, it would really set the bumper off (and be more functional) if you ran another row of tubing that wrapped the truck below the single row.  And then connect the two with uprights at like 12" O.C.  Not trying to be too critical, just throwing out ideas.  Good work mang.Lots of toys.
Reply:Great job!it looks pretty cool and it seems that you saved a little cash...what are we buying with it?My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Nice job. Who makes that bender and how much was it? Was everything bent on it?
Reply:Originally Posted by zapster Thats  But none the less..There is a drill press against the wall down front..And a big patch of hair stapled to the wall behind it with a message that reads.."Watch for the spindle"Just be careful out there..Even a drill press will hurt ya..And they don't say "sorry" afterwards... ...zap!
Reply:Originally Posted by yellowNice job. Who makes that bender and how much was it? Was everything bent on it?
Reply:Actually Paul its a Pro-Tools 105, but they're all essentially the same anyway. It does a great job, and I beleive it was about $470 delivered including the die. Does a really nice job on the bends once you get the hang of setting it up, getting a 22ft stick of tube into it is a bit of a chore, but I'm diggig it so far.Brandon75173, I had considered another tube, or even some plate gussetts, but considering the wheeling I do, and how long it took me to bend my old bumper I decided the extra weight savings and ground clearence were more valuable than the extra, and I beleive unwarented, strength. I guess if I do bend it I could make a new one though.All the money I saved, will make by building a few more of these will go toward buying an early 90's f250 for a deisle pre-runner project, I want to go to Mexico, jump it on Zoo Rd. and then be able to dump used cooking oil in the tank for an enviromentaly freindly good time.
Reply:and, it's done
Reply:Looks GREAT!! Now it's time to go try it out -Cory
Reply:Bumper looks GREAT.  About the sunburn tho...  I brought a new welder home once when I was living at my parents years ago.  I have a pic somewhere of my dad trying it out... a Miller Bluestar...  HE was so excited ran over from the pool in speedos and flip flops to give it a whirl.  What a nut.  HE got torched, holes thru flip flops and all .  I asked him why he even bothered to wear a hood!?Patching farm equipment with 2 old 6 volt batteries, some jumper cables and a box of 6010 left out in the rain last night
Reply:looks really great. now all you have to do is go get stuck in some mud bog so you can test out the winch.http://datingsidorsingel.com/
Reply:New Bumper looks great.  Nice Rover too.Favorite right now is a Miller Syncro 200.Tons of tools and I blame at least one of them when things don't go right.
Reply:Nice work! Thanks for the step-by-step pics. Now you just need to wash the truck!Oh, nice car in the garage, whatever it is.Last edited by Carl26; 07-05-2007 at 10:31 PM.Lincoln AC/DC 225/125 Stick Linde HDA-300 MillerMatic DVI MIG Miller Dynasty 200DX Hypertherm Powermax 1000
Reply:Originally Posted by Carl26Nice work! Thanks for the step-by-step pics. Now you just need to wash the truck!Oh, nice car in the garage, whatever it is.Your Rover bumper Looks awesome!  (good dog, sit rover, sit!  Good girl, now plow through the mud!)
Reply:Awsome bumper.  Looks like a Discovery Series II?  That is a very soon project for me - My 99 Range Rover needs a bumper and a canoe/safari rack badly!  FINE 4x4.  Pulls around stuck jeeps all day long with street tires on it!Gonna look really cool pulling the welding trailer through the slop to fix a broken jeep somewhere!!  My other truck is a 1976 IHC Scout II (Rover Recovery Vehicle).      Nice job!Rob PageMiller Bobcat 250Lincoln SP170-T