Rear bumper mock up

[Nrobert10]

Looking good! Your work is always impressive!

[boywonder]

Originally Posted by Glider

With those beefy shrubbery guards, do you still feel the need for a bracket to the upper door hinge? Are you seeing movement?

Yes, lots of movement without connecting the swingarm support stuff to the hinges....huge difference.

[boywonder]

I got a little more done on the project.....fabricated aluminum brackets to connect the swingarm supports to the upper door hinges.



Getting close to the end...I still need to fabricate an aluminum plate for the right swingarm, and fab a sealable "hem" for the hatch....then everything gets powder coated.

[MSD]

Originally Posted by boywonder

I got a little more done on the project.....fabricated aluminum brackets to connect the swingarm supports to the upper door hinges.



Getting close to the end...I still need to fabricate an aluminum plate for the right swingarm, and fab a sealable "hem" for the hatch....then everything gets powder coated.

Super slick and very clean, Liking how this is all coming together.

[JWA]

VERY late to this thread but WOW Boywonder even now very impressive work and results too. I don't need such bumper but love watching the progress from concept to working product. Massive kudos! Curious about something though..........

I had no idea aluminum could be milled with a router. If its not too much a distraction could you detail how you accomplished that? Variable speed router? What sort of mills were used?

[boywonder]

Originally Posted by JWA

Curious about something though..........

I had no idea aluminum could be milled with a router. If its not too much a distraction could you detail how you accomplished that? Variable speed router? What sort of mills were used?

haha.....I'm not that talented......

I have a full sized milling machine, large rotary table (needed here), lots of tooling......in my garage....

....and a tiny Harbor Freight lathe....planning on selling that and getting a slightly larger lathe.....

I've been contemplating rounding over the edges with a 1/4" roundover bit and my router table but haven't attempted that yet.

[JWA]

Originally Posted by boywonder

haha.....I'm not that talented......

We'd disagree on that, having seen your progress on this project.

Oh well, I was hoping for some magical way to mill aluminum with simple woodworking tools.

[MotorbikeBruno]

Any updates on this, I've just read through the whole thread. Wow! Quite amazing work from start to finish!!

[boywonder]

Originally Posted by MotorbikeBruno

Any updates on this, I've just read through the whole thread. Wow! Quite amazing work from start to finish!!

Yes! Recently work has consumed my life......it's sooo overrated...but I found some time to work on this.


.....So I got everything fitted up and dialed in.....that only required bumper install and removal about 35 times...then off to the powder coater.


I brought one of the Aluminess swing arms to the powder coater for color reference, and ordered a Matte UV resistant black....five days later I picked up this:








Assembly starts:

[boywonder]

box assembly:






Hinge and hinge bracket:






Swingarm stop pins: ...the receiver part is delrin....pull pins are stainless






Rear LED and backup sensors: ...the backup sensors are installed in grommets. These grommets are Buna-N; not rated for outdoor use....the rubber degrades over time, I'm ordering silicone O-rings to replace these.






Hatch: I'm planning on weatherstripping the hatch opening, and the wiring is not yet dressed in this shot. I'm planning on dressing the wiring against the top surface of the bumper.






Rotopax mount: ...by dumb luck, the 2 gal rotopax fits perfectly in the side pocket of the box assembly as well. This is nice feature since mounted where shown here is a problem when the moto is loaded on the back of the van.






One more pic of the whole setup: