I am sure everyone is getting tired of seeing renderings of this design process, but I really think I am getting close to a finalized design and hoping this will be one of the final design revisions!
A few things that I have tweaked:
- I remeasured the existing bumper mounting brackets and modeled them to better refine the mounting situation. The plan is to modify the factory mount to allow the mount to run further in on the outside and bottom of the frame rail utilizing the factory hitch mounting holes.
- After measuring the existing frame rails and mounts I realized that the main vertical face of the bumper was going to be slightly too short causing the bottom of the frame rails/mount to hang lower than the bumper's bottom edge. So I increased the height slightly making the bumper a bit chunkier but I think it still works with the front Aluminess bumper lines and keeps true to the original design.
- I revised the brush guard design to better fit around the lights by using a compound angle similar to the Aluminess design.
- I took the advice of boywonder and redesign the inner webbing of the bumper to minimize some of the the open areas of the bumper. I still have a fair amount of holes just to make it easier to access things like the light pods or the pivot bolt/nut but I think it's better than before. Also currently, the design is still using 3/16" so I still have holes to allow for weight reduction.
- I looked closer at how I plan on doing the pivot points and think I found a solution utilizing two dual tapered roller bearing setup with a bushing and a grade 8 3/4" bolt through the full assembly. (See the isometric section picture below).
- I again took the advice of boywonder and an upper pivot that ties into the brush guards with the possible option to tie those into the door hinges. This pivot can use a simpler bolt and bushing setup instead of a more complicated bearing system like the lower pivot.
- In adding the upper pivot I also redesigned the upper swing arms to allow them to better utilize the upper pivot point as well as cut out more weight of the panel by switching the design to a "MOLLE" pattern rather than just holes.
- I also added radio mounts on top of the brush guards for things like a weBoost antenna or a GMRS radio antenna. Probably not the most ideal spot for the best range but I would rather them blend in with the van and not stick up and above the roof line too far. Got to keep my garagability!
- The last thing that I added to the model just to better show the functionality of the bumper was my previously modeled 1up Bike rack and bikes just to test how far I can open the swing out. Based on this model it's over 150 degrees so not too bad!
I have started doing some quick cardboard mock-ups just to confirm I am not screwing any dimensions up as it's a bit tricky to get the wrap around part dialed in with the contours of the body but I think I am close! Hopefully, all this time spent in the design phase will pay off in the end and make the construction stage of it much faster.
Thanks again to everyone who has been chiming in on this thread and giving me good tips/ideas. Hopefully, I'm not boring everyone with these endless revisions and some still believe that this will actually turn into a real world bumper and one day leave the modeling world!
Below are some pictures of the latest revision with the above changes incorporated. Let me know what you think and if you have any suggestions.
Bottom pivot isometric section cuts
W/ Bikes & Bike Rack On and Swing Open
Bumper w/ Poor Quality 3D Scan
This will still need to be capped at the wheel well and a rubber gasket will be installed between the bumper edge van body. Fender flares will be modified to die into the bumper.
Isolated Bumper Structure