built an aluminum bumper today

[rjrobin2002]

I dont know how to build saw horses and they seem complicated. Plus those have not collapsed yet. LOL

 

[frenchy]

Guess I should have read this post the right way, duh, sorry about that. I have a older hobart welder but it's not spool gun ready. Went to a Big R farm store today for the first time, just opened not long ago. Of course had to see what they had for welding stuff. Couldn't believe there 190 and 210 Hobart welders are spool ready and they have the spool guns for $199.99. Wheels are turning, always wanted a spool gun for alum in my shop. What setup do you have?

frenchy

5356, 4043 is a lot weaker weld from what i read so i dont use it even though it does make a much prettier weld.

 

[rjrobin2002]

I have a miller 252 with the 30a spool gun. I have a hobart spool gun only used one tank i will sell you. I need to go look at what model it is. I had it on a welder that was to small to weld aluminum.

 

[bmc69]

Me too, i use pierce aluminum also out of Broussard La. What size channel did you use to fit in the frame?

I'd have to measure..but I'm thinking it was 2 x4". I'll double check next time I'm in the shop.

Update: I used 1.75" x 4" channel. But if I had purchased it just for the inserts and not just found something out in the stockpile, it would have been 2" x 4".

 

[Unaweep]

Nice bumper, did you weld the inside seams also?

 

[rjrobin2002]

Yes both sides. I have found aluminum welds are not strong unless both sides are welded in my boat building experience. Only problem is when its a side that a spool gun cant fit.

 

[BradtheWelder]

What does it weigh? I'm curious if it is a huge difference or not.

 

[Unaweep]

What does it weigh? I'm curious if it is a huge difference or not.

The aluminum bumper should weigh about 2/3's less than the same design in A36 steel, but I'm guessing this bumper would be a bit heavier as it's built from some hefty aluminum, I don't know if you would need steel that thick.

I like it.

J.E.

 

[fordfan]

I made my bumpers on my trail rig of aluminum and the front bumper without the winch weights 60 pounds. The main plates are .500 6061, so it is plenty strong. The attachments to the frame are also 1/2" thick with 3 bolts per side. The rear doubles as an air tank.

 

[NGABronco]

Yeah fordman, those are nice bumpers and I bet you rebuilt the carb on "Patches" in the bathroom at the Hampton Inn in Oakridge,TN;D;D;D

 

[fordfan]

Yeah fordman, those are nice bumpers and I bet you rebuilt the carb on "Patches" in the bathroom at the Hampton Inn in Oakridge,TN;D;D;D

Auh Ben! Your old enough you should have forgot that!;D;D

 

[rjrobin2002]

It is under 50 pounds cause i can pick it up easy with one hand. Only the center winch section and frame mounts are 3/8", there is a combination of 1/4", 3/16", and 1/8" on the non structural outers. I will weigh it and clean up the welds and dirt off it the next day i am off and get some better pictures.

 

[rjrobin2002]

I did some brushing of the aluminum, cleans up nice. I am gonna finish a few welds and grind all the welds smooth when the snow melts.

 

[bmc69]

Looking good.

Painting with same system yr using on the boats?. I'm getting the aluminum bumpers and the aluminum full roll cage for the '69 powder coated black once they are finished. I wouldn't normally do that...but since its going to be a street queen, I'm not as worried about scratches.

 

[rjrobin2002]

Gonna brush it just for the heck of it in case someone wants it that way. I will acid wash it and stromium chromate prime and paint or bed line it if someone wants it. I may throw it on my 75 if it wont sell.

 

[br0nc0xrapt0r]

I think you are going overboard on the alum thing and I love it ;D You ought to throw some polish on this thing and do the acid etch bronco emblem like I did on my dash pod.

 

[rjrobin2002]

I forgot about that. Post up a picture, that was awesome.

 

[Bluebolt]

Nice work Robin, I met you last year when you were pulling an explorer motor out of upullit on Aero drive. I just got my first early Bronco, I am up in Benton.

 

[br0nc0xrapt0r]

I polished the whole sheet then I made a stencil and painted the bronco script with the wifes clear nail polish and submerged the whole thing in muriatic acid. I think it was in there for about 5-10 min. It made the background nice and flat and the script was still reflective.

I think it would be cool if you polished the whole bumper and made a acid etched script.

 

[jmeyer1971]

Nice work Robin, I met you last year when you were pulling an explorer motor out of upullit on Aero drive. I just got my first early Bronco, I am up in Benton.

I think you are going overboard on the alum thing and I love it ;D You ought to throw some polish on this thing and do the acid etch bronco emblem like I did on my dash pod.

Or those naked ladies you see on mud flaps