Bumper build design and strength question

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Afternoon Folks! I have a bumper build I would like to do and would like y'alls thoughts and advice on strength of this and will it hold up properly and not become shrapnel in an accident. I would like to build this to the point that even (in the event of an accident) after my '93 f-250 is a crushed pop can the bumper will still be intact. Here is what I want to do in a very rough sketch:It lacks a few details but I was short on time when I drew this. The actual bumper will have the upward cut in front of the tires, fog lights, a winch (12,000lbs-15,000 capacity), expanded metal in between the tubing (center section), built in trays on top for tools while working, and a couple other personal touches.I intend to use 2" tubing, perhaps 5/16" thick. 2 sections of 1/2" plate (attached to the tubing), and the bumper itself will be 3/8" material.It will have gussets in the back and whatnot for structural support. Is there anything else y'all an think of to add to this (functionality)Those that know structural properties and those that have done this before: thoughts, important details, lessons from a build?  HW, 1965 lincoln idealarc 250 ac/dcEastwood mig135And a bunch of other random stuff.
Reply:The 3/8" plate head on like that does not have a lot of strength in that direction. Would it be adequate? Yes but not indestructible.
Reply:Heavy duty front springs and reinforcing of the front frame come to mind after looking at that list.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:If this is going on the F-250, you better plan on building one of equal weight to go on the rear, so the back tires can stay on the ground for traction. That sounds like it is going to be quit a bit of weight hanging off the front. Maybe mount dual wheels on the front end, too, to carry the weight better without sinking into the mud too bad.
Reply:Originally Posted by BistineauIf this is going on the F-250, you better plan on building one of equal weight to go on the rear, so the back tires can stay on the ground for traction. That sounds like it is going to be quit a bit of weight hanging off the front. Maybe mount dual wheels on the front end, too, to carry the weight better without sinking into the mud too bad.
Reply:WAY to much metal. 1/8"-3/16" on the tubing wall is as big as I'd go, and 1/4" on the plate. with maybe 3/8" for the uprights. part of the point of a bumper is to absorb the impact. it does this by moving some. otherwise you're sending the impact all the way up the frame, and potentially obliterating anything you hit.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Originally Posted by ThorsHammerWAY to much metal. 1/8"-3/16" on the tubing wall is as big as I'd go, and 1/4" on the plate. with maybe 3/8" for the uprights. part of the point of a bumper is to absorb the impact. it does this by moving some. otherwise you're sending the impact all the way up the frame, and potentially obliterating anything you hit.
Reply:Don't forget that the force is transferred both directions in an impact so if you hit another vehicle, the entire force is being transferred into that vehicle. Potentially causing catastrophic injury to the occupant.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Yeah, figures that I would overkill it. But, of I go with that material thickness, I have a new issue. Warpage, under no circumstances will I use mig other than to tack this project together. 3/32" 7018 should be fine given stops and starts, cooling periods, and the surface area. But I would like to minimize stops and startd and run an electrode without concern. Any suggestions on this issue?HW, 1965 lincoln idealarc 250 ac/dcEastwood mig135And a bunch of other random stuff.
Reply:Originally Posted by ThorsHammerDon't forget that the force is transferred both directions in an impact so if you hit another vehicle, the entire force is being transferred into that vehicle. Potentially causing catastrophic injury to the occupant.
Reply:you mean you won't use a 110 mig on it. I'd step up and use mig all day on a bumper build.68' redface64' redface78' blackfaceSquarewave 200Trailblazer 302Miller 12vsMillermatic 211Maxstar 150325 Xtreme Victor cut master 52Betenbender shear& brakeScotchman iron workerWellsaw
Reply:3/8" thick covering!? good lord man...I would do 1/8" at the absolute thickest, and that's if there isn't a underlying structure...Welding/Fab Pics: www.UtahWeld.com
Reply:Originally Posted by Brettlivyou mean you won't use a 110 mig on it. I'd step up and use mig all day on a bumper build.
Reply:Overkill is totally underrated.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:Originally Posted by Hobby welderI wont even use a 220 mig, I hate the process. I can do it in every position really well but I just dont like it.I want and will stick weld this. Stick looks nicer too, to me its a little more gratifiying.I have access to a miller 250 if I so desire but its a snooze. There are some projects i wil mig when my idealarc isnt an ideal choice.
Reply:Too thick for my liking, but it's your build.No matter how thick your material, it will still distort when welded.  It'll just be harder to straighten."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Never go full retard.My name's not Jim....
Reply:Originally Posted by BoostinjdmNever go full retard.
Reply:Originally Posted by BrettlivHa yeah sure.
Reply:Cool deal let's see some bumper pics.68' redface64' redface78' blackfaceSquarewave 200Trailblazer 302Miller 12vsMillermatic 211Maxstar 150325 Xtreme Victor cut master 52Betenbender shear& brakeScotchman iron workerWellsaw
Reply:Originally Posted by BrettlivCool deal let's see some bumper pics.
Reply:I would use like 1" or 11/8 plate and make sure to weld it to the frame for extra strength68' redface64' redface78' blackfaceSquarewave 200Trailblazer 302Miller 12vsMillermatic 211Maxstar 150325 Xtreme Victor cut master 52Betenbender shear& brakeScotchman iron workerWellsaw
Reply:I will look some time this week to see what the front and rear frame ends have on them. I know when my parents bought the truck brand new they requested a few extras such as heavy duty springs and frame reinforcements.HW, 1965 lincoln idealarc 250 ac/dcEastwood mig135And a bunch of other random stuff.
Reply:I was just joking don't weld anything to your frame. And 11ga will be plenty for a bumper.68' redface64' redface78' blackfaceSquarewave 200Trailblazer 302Miller 12vsMillermatic 211Maxstar 150325 Xtreme Victor cut master 52Betenbender shear& brakeScotchman iron workerWellsaw
Reply:3/8" plate weighs 15 pounds per square foot. Assuming his bumper is 10" tall and 6 feet wide the plate will way 75 pounds. That isn't exactly going to overtax a 3/4 ton truck. I would recommend using a piece of channel iron. I have built several bumpers out of it and they are stout without being too heavy. I have annihilated several deer with them resulting in zero damage to the truck. 1/8" material will bend if you hit a deer going 75 mph.got any pics of the channel bumpers?68' redface64' redface78' blackfaceSquarewave 200Trailblazer 302Miller 12vsMillermatic 211Maxstar 150325 Xtreme Victor cut master 52Betenbender shear& brakeScotchman iron workerWellsaw
Reply:Hobby welder, how's that Idealarc treating you?"USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:http://weldingweb.com/vbb/showthread.php...per&highlight=Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Finally had time to actually copy some of the pics from that thread here. Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Originally Posted by OldendumHobby welder, how's that Idealarc treating you?
Reply:Originally Posted by irish fixitFinally had time to actually copy some of the pics from that thread here.
Reply:That's just a standard Ranchhand grill guard welded to the bumper I made from 8" channel. The thread I referenced earlier has more details.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:HW, 1965 lincoln idealarc 250 ac/dcEastwood mig135And a bunch of other random stuff.
Reply:Originally Posted by Drilldo1/8" material will bend if you hit a deer going 75 mph.
Reply:Originally Posted by Brettlivgot any pics of the channel bumpers?
Reply:While we're at it, does anyone have ideas on how to get these to function with airbags?Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Originally Posted by Hobby welderI wont even use a 220 mig, I hate the process. I can do it in every position really well but I just dont like it.I want and will stick weld this. Stick looks nicer too, to me its a little more gratifiying.
Reply:Originally Posted by Robert HallWhile we're at it, does anyone have ideas on how to get these to function with airbags?
Reply:Originally Posted by abecthe airbags are triggered off a impact sensor usually there attach in the front end not on the bumper
Reply:Originally Posted by AKmudYou really think stick welds look better than good MIG welds.....? Not too sure you are as good at MIG as you say you are.
Reply:Originally Posted by Robert HallI probably agree, however IIUC, the impact shock from a stiff bumper will set them off much more easily than they should be.Kinda like that video with the grandma in the crosswalk whacking the car with her umbrella and the airbag going off.
Reply:Originally Posted by Hobby welderWell, stick welds have definition, GMAW is plain. Its like putting glue on the surface, not much to it. Call it "character" if you like. Its a personal thing.