Rear bumper mock up

[boywonder]

Here's some masking tape, a 2x8 and a sheet of 1/8" MDF put to good use......about $18 worth of stuff...



Hillbilly bumper:




Used the stock bumper for the body contour on the top of the mock up...





Starting to look like a bumper:





Final (for today)..a few refinements....rear surface of bumper angled, step cut out...I'm torn between having a step and having more storage






The plan is to either fabricate the bumper pieces and find someone to weld it, or perhaps have a sheet metal shop fab the parts and weld them...and then powdercoat. Working on a Solidworks model presently.....going to add some surface mount LEDs, storage space (hopefully) and a few other features...open to more ideas! .....spare tire holder, box.....

[mgmetalworks]

Looks like the corner of that step would hurt if you happened to fall on it.

[86Scotty]

I love the shape. I wonder if you could put a step inset in the face of the bumper, think newer Chevy pickups with those cool inset corner steps, then you could have a door along the top with storage? I sure loved that in my Airstream trailer!
Of course, this would only give you a step up and not a step down but that might be all you need. I very rarely walk out of the back of my van but have stepped up many times to reach something inside or while washing, etc.
Another downside to this idea might be the lack of a center license tag spot but you could always put it higher, and more visible on a box or in the stock location if not covered by a box.

Looks great though!

[boywonder]

Originally Posted by mgmetalworks

Looks like the corner of that step would hurt if you happened to fall on it.

MDF machines up real nice......


I can see what kind of radius the sheet metal shop can do......not sure I'm keeping the step........of course after TIG welding the sharps corners are a bit rounded.

[boywonder]

86Scotty: yes, I did notice those inset corner steps the other day driving down the freeway since my bumper awareness has been increased...

..interesting idea...

[BajaSportsmobile]

Is this going to be steel or aluminum?

[boywonder]

Aluminum.......thinking 3/16"

...either 5052 or 6061....going to talk to the sheet metal shop about it.

Edit: it looks like 5052 is the material of choice.....more formable (there are a few bends) and no need to heat treat after welding)......or perhaps 3003

[BajaSportsmobile]

I'd probably use 6061 and would not worry about any heat treating.

Cut it yourself with a Carbide Skill Saw and use a Router to clean up the edges before and or after welding. Treat it just like wood...

You can rent a Spool Gun and weld it yourself quickly and easily. Any voids in welded seams can be re-welded or filled with All Metal filler and then Powder Coated.

[rallypanam]

Looks good. My question is.. why didn't/don't you go with Move?

[boywonder]

Originally Posted by BajaSportsmobile

I'd probably use 6061 and would not worry about any heat treating.

Cut it yourself with a Carbide Skill Saw and use a Router to clean up the edges before and or after welding. Treat it just like wood...

You can rent a Spool Gun and weld it yourself quickly and easily. Any voids in welded seams can be re-welded or filled with All Metal filler and then Powder Coated.

Ramsey: Yes I've been toying with the idea of cutting the sheets....my non ferrous blade will cut this stuff like butter. There are a couple of shallow bends...thinking of kerfing/scoring the sheet on the tablesaw and then bending with 2x4's and clamps or vice, etc.

I'm also thinking about a couple of pieces of 2x8" AL channel for the support that bolts to the van. I don't really need a full length channel although if I find a rem at IMS.......that would give the top and bottom something significant to weld to.

I can certainly make the cut-outs for the flush mount LED's that I'm thinking about.....and I've got an idea to easily mount the back-up sensors cleanly....the factory sensor holders have ears in crazy places.

If I do the step part.....that's a fair bit of bending...or just weld individual sheets in there.

I have a super-crapilicious 240V Harbor Freight MIG welder with a gas bottle...the gun completely sucks though.....instant bird's nest when pulling the trigger. When I bought off of CL I figured the bottle and regulator were worth the $60 I paid for the whole thing.