Home made rear bumper! - Defender Source
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  #1  
Old May 8th, 2005, 10:18 PM
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Yousef Hamzeh
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Home made rear bumper!

Wasn't sure if I wanted to build the bumper, or have the ability to build one anyway but I finally decided to go with it. We thought about buying one from RW but I promised the girlfriend that she will spend little to none $$ on her D90 and I will make it one of the best in the country based on selling what she has on it and use my resources Her D90 wasn't setup right for the $$ she put on to it but soon she'll have one rockin D90

Thanks to Keith for answering all my questions, and Mike Hanson for letting me borrow his welder and miter saw. I owe you guys

Keep in mind this is the first time I ever built something out of steel. I used 3/8" steel plate for the mounting brackets and quarter panel plates/sliders, and 2X3X3/16 square tubing. I tack (spl) welded everything together as I still don't trust my welding, two days of welding is not enough to weld a bumper but will keep practicing and hopefully I can weld this thing together b/c she wants this bumper to be built by me only w/o any help. I still need to grind and make things look pretty.

Oh yeah, total cost is $70 and this thing should take all the abuse that it can take. Also I'm planning on installing a swing away tire carrier and 2 jerry can holders.

I will post the final the completed pictures soon.

More stuff to build soon
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  #2  
Old May 8th, 2005, 10:46 PM
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Yousef,
Nice job. Tell me you were not using your Powertank (CO2) for shielding while you were welding.
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  #3  
Old May 8th, 2005, 10:48 PM
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Yousef Hamzeh
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No, my frined was using it to air up his tires. It just happen to be there.

What's wrong with shielding anyway?
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  #4  
Old May 8th, 2005, 10:51 PM
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Good. I've seen people weld with you name it for a gas shielding and the welds are very brittle, and weak. CO2 usually cools the puddle to fast and the weld just cracks.
Once again, very nice fab-up. Jesse James and the Monster Garage boy's would be proud of you!!!
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  #5  
Old May 8th, 2005, 10:54 PM
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Hehe thanks
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  #6  
Old May 9th, 2005, 04:44 AM
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Looks fine.
Did you think of any internal plate to spread eventual strain?
I see the receiver hitch.
The xmember bends easily...
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  #7  
Old May 9th, 2005, 07:08 AM
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WOW! Nice work! I like it!
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  #8  
Old May 9th, 2005, 09:16 AM
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Yousef Hamzeh
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The only way I can do this is bolt/weld the bumper to the X member. There is a plate on each end that will be welded to the X member. The corner protectors also have plate on each side that will be welded to the x member.

I remember my old Rock ware bumper using 6 bolts only and it did its job perfectly. I have 8 bolts plus it will be welded.

I hear you on the x member and yes mine is bent but I have a plan for cutting off my x member and welding some beefy square tubing in its place for more strength and clearance. The only way I though about to reinforce the x member is to triangulate the ends by welding a tube from the corner to the frame. Now the Yellow D90 wonít see any hard core trails so Iím not too worried.
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Old May 9th, 2005, 09:51 AM
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Nice looking bumper! Hey, where did you find a rare 1 TON Defender?
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  #10  
Old May 9th, 2005, 10:03 AM
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Thatís just funny, when I wrote this signature I knew if some one is going to ask about the 1 TON itís going to be you So to clear it up I was talking about my drive train, not frame or the whole truck
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  #11  
Old May 9th, 2005, 10:13 AM
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I aim to please. Bumper looks great, good job.
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  #12  
Old May 11th, 2005, 09:31 PM
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Nice work Yousef!!!!
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  #13  
Old May 11th, 2005, 09:39 PM
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Looking good there! Amazing how totally different the back of yours looks compared to mine, I am seriously considering going to the newer style tail-lights for my 94.

Dave... I'm in the market for a welder in the very very near future, but that's the one topic I can't find good info on is the shielding gasses. What's your recommendation?

-Hans
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  #14  
Old May 11th, 2005, 10:54 PM
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My Hobart Welder The one Yousef is using (Very good for the money) came with a manual that sugests the proper gas mixtures for welding different materials Argon / CO2. percentages

If you loose the manual it is printed on the inside cover plate of the welder. For general fab work use intersheld wire and not mess with the gas.
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  #15  
Old May 11th, 2005, 11:50 PM
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There's one problem with that Bumper Yousef, it looks almost exactly like mine. Does this mean there are some monkey bars in your future?
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  #16  
Old May 12th, 2005, 10:33 AM
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Hehe, what you are trying to have me killed? Post a picture of your bumper, I would like to see it. Hopefully I can have her's done tonight.
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  #17  
Old May 12th, 2005, 11:14 AM
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Looks good Yousef. Nice and beefy. It looks like mine too and alot cheaper.
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  #18  
Old May 12th, 2005, 09:03 PM
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It's done! I'm so proud of myself
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Old May 12th, 2005, 09:07 PM
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That is sweet! Buttercup is looking good
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  #20  
Old May 12th, 2005, 09:15 PM
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Thanks. I was suprise how well it came out. It looks like I'll be in the market looking for a welder and tube bender
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