| Author |
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Dave_Lucas (Dave_Lucas)
| | Posted on Wednesday, December 11, 2002 - 03:31 pm: | 
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Here are some pictures of the bumper that I just made for my DII, this project all started with a trip to Moab and spending the entire weekend dragging my rear bumper over every obstacle. I started out with the hope of increasing my departure angle without allot of trimming on the body and to have the end product look decent.
Materials used:
3/16 steel tubing
3/16 steel flat stock
Steel pipe for corner braces
SMB recovery points from Expedition Exchange
Grade 8 12 MM bolts
12 MM Weld nuts
Land rover trailer hitch wiring.
Tools used:
14� Chop Saw
Millermatic 210 Mig welder
4 ½ � Grinder
90 Degree angle grinder (Air)
Normal Angel Grinder (Air)
16 Speed Drill Press and several different style/size of bits.
Several clamps
I am happy with the overall outcome of the project, however I do plan on adding a few items in the future such as a 2� receiver hitch, a hoop to protect the spare tire from a rear impact and possibly high lift jacking points.
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Mike Holmes (Myktoolbox)
| | Posted on Wednesday, December 11, 2002 - 03:38 pm: |
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daves got skillz. 'nuff said. |
Dave_Lucas (Dave_Lucas)
| | Posted on Wednesday, December 11, 2002 - 03:40 pm: |
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Dave_Lucas (Dave_Lucas)
| | Posted on Wednesday, December 11, 2002 - 03:42 pm: |
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I will post some pics of it in the finished form tonight when I get home.
Thanks Mike, |
Greg Davis (Gregdavis)
| | Posted on Wednesday, December 11, 2002 - 03:43 pm: |
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Very nice. Got a better side view? |
Blake Luse (Muddyrover)
| | Posted on Wednesday, December 11, 2002 - 04:03 pm: |
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man i didn't know they had diet mountain dew code red
also do you have an pics from farther away |
Paul D. Morgan (V22guy)
| | Posted on Wednesday, December 11, 2002 - 04:47 pm: |
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Very nice Dave. What is your plan for the exhaust? |
Dave_Lucas (Dave_Lucas)
| | Posted on Wednesday, December 11, 2002 - 05:31 pm: |
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Ok, here are the pictures of it mounted, if you want to see any other shots let me know
Greg, were the side shots what you were looking for?
Blake, The wife started buying me diet for some strange reason? The code red diet stuff is the best I had tried so far
Paul, I think I am going to remove the resonator and have the pipe end just short of the bumper, not sure though. |
Dave_Lucas (Dave_Lucas)
| | Posted on Wednesday, December 11, 2002 - 05:36 pm: |
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 |
Jack Herman (Jackson)
| | Posted on Wednesday, December 11, 2002 - 05:45 pm: |
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Make me one ! Great job. |
Dave_Lucas (Dave_Lucas)
| | Posted on Wednesday, December 11, 2002 - 05:45 pm: |
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 |
Kyle
| | Posted on Wednesday, December 11, 2002 - 06:07 pm: |
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Damn man. Hell of a job..... looks nice..
Kyle |
Rob Davison (Pokerob)
| | Posted on Wednesday, December 11, 2002 - 06:13 pm: |
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follows KISS perfectly
great job
rd |
Clif Ashley (Cta586)
| | Posted on Wednesday, December 11, 2002 - 06:14 pm: |
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Extremely well done - going into production yet? |
John Lee
| | Posted on Wednesday, December 11, 2002 - 06:31 pm: |
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Holy shit. That is nice! That's definitely no home-made POS. Great job. |
Blue (Bluegill)
| | Posted on Wednesday, December 11, 2002 - 06:39 pm: |
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looks like it could be standard equipment
man I wish I had a custom bumper....... |
Chu
| | Posted on Wednesday, December 11, 2002 - 06:49 pm: |
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That's great Dave! You get laid off or something? Can't wait to check it out in person.
chu |
kyle
| | Posted on Wednesday, December 11, 2002 - 06:49 pm: |
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Shuddup blue...
Kyle |
Tripp Westbrook (Tripp)
| | Posted on Wednesday, December 11, 2002 - 06:54 pm: |
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Hey what's the little plug thingy in the middle of the bumper for?
I suppose you had to remove the hitch since it hurts your departure angle. Too bad.
Looks great! |
Carter Simcoe (Carter)
| | Posted on Wednesday, December 11, 2002 - 06:55 pm: |
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Damn, thats one of the best home-made ones I've ever seen. The shackles are a nice touch. |
Alen
| | Posted on Wednesday, December 11, 2002 - 07:09 pm: |
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Kick ass bumper Dave, are you going to add a skid plate for the tank?
Would do sides take a good hit without bending?
Alen |
Erik G. Burrows (Erik)
| | Posted on Wednesday, December 11, 2002 - 07:21 pm: |
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Really good job Dave. Congrats! |
Michael Villanueva (Michael)
| | Posted on Wednesday, December 11, 2002 - 08:22 pm: |
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Wowza!!! Sweet, sweet, sweet! It is an honor to look at the damn thing! |
Tom V (Cozmo)
| | Posted on Wednesday, December 11, 2002 - 09:30 pm: |
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WHOA that a nice bumper |
Dave_Lucas (Dave_Lucas)
| | Posted on Wednesday, December 11, 2002 - 10:12 pm: |
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Wow,
Jack, Rob, Cliff, Blue, Cartner, Erik, Michael, Tom,
Thank you all for the kind comments
Kyle,
Thank you, oh master of the KVT bumper, I appreciate the kind words!  .
John,
Thank you, the SMB�s from Expedition Exchange worked out great, now I just need to find someone that I can recover with them.
Chu,
Nope not laid off, needed the therapy that building something from scratch provides and did not want kick out the $$$$ for what was out there, not to mention I would rather spend the money on some tools.
Trip,
The plug is the land rover factory trailer wiring harness; normally it sits lower than the 2� factory receiver and was almost ripped off several times on trails. The hitch was removed as you stated to improve the departure angle, however I will be adding a 2� receiver to the bumper this week or next, I will lose a little clearance, but I need it to tow my dirt bikes.
Alen,
I do plan on adding a skid plate to the bumper to help protect the gas tank, in my opinion without the factory hitch there it would just be asking for trouble. Now on to the tough question, would it take a hit from the side and survive? To be perfectly honest I do not know, but here are some situations and what I think would happen.
Direct hit on the side from a car: Most likely would see severe bending and need replaced, I thought about putting in a brace to the frame to make the bumper withstand a side impact, but after some thought I decided against the brace as it would apply the force to the frame of the vehicle, personally I would rather replace the bumper than have to get frame work done. I did however brace the bumper from the side to the rear of the bumper with a 2� pipe to add extra strength.
Resting against a rock or sideway slide into a rock: I think it would be fine, you can not see it but most of the side of the bumper with the exception a few inches here and there are 2� 3/16 tubing that is braced to the rear portion of the bumper.
But as I said to be honest I do not know, but I personally think it will do what I want it to, and it has to be stronger than the stock plastic POS.
And finally to answer everyone that asked when or if I will sell them,
I honestly have not thought about selling them, I enjoyed building this bumper and the sense of accomplishment that came with it, it is a great feeling the first time you step back and look at it, but it is allot of work and heavy lifting for one person. I have promised to build a few for other DII and DI owners here in Colorado as long as they would help me build it, but I may see if someone in Colorado would be willing to help me build a few in trade for making one for them.
If you are seriously interested let me know and I will see if I can get someone to help me build you one.
And if anyone in Colorado with a DII is interested in letting me build one that would extend to the rear wheel well let me know, I think it would be fun but I have not got up enough courage to cut off the lower part of my quarter panel yet  |
Jess Alvarez (Jester)
| | Posted on Wednesday, December 11, 2002 - 10:18 pm: |
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Dave,
Sweet JESUS! Nice looking bumper. Good job, man. Let us know how it holds up.
Jess
O2D2 |
Carter Simcoe (Carter)
| | Posted on Wednesday, December 11, 2002 - 10:18 pm: |
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That is a really good idea with the light plug. I think I am going to cut a hole in my stock bumper and put my light plug in it like you did on yours. I have bent the braket up to many times to count and I am just waiting for it to get ripped off. |
Ron A
| | Posted on Wednesday, December 11, 2002 - 11:10 pm: |
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Dave very nice job.
Aren't flap disks just about the best invention ever made. (LOL)
Ron A |
Dave_Lucas (Dave_Lucas)
| | Posted on Wednesday, December 11, 2002 - 11:27 pm: |
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Ron,
Yes, but my favorite is the little scotch-brite roloc pads that go on my 90 degree angle grinder.
They are great for finish work or removing old gaskets I will never use a gasket scraper again |
Greg P. (Gparrish)
| | Posted on Thursday, December 12, 2002 - 08:56 am: |
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Great job, Dave. Looks awesome. |
Rans (Rans)
| | Posted on Thursday, December 12, 2002 - 09:09 am: |
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Great bumper Dave, you could make a living of these I bet!! |
gp (Garrett)
| | Posted on Thursday, December 12, 2002 - 09:19 am: |
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very damn nice. and i dig those tires. |
muskyman
| | Posted on Thursday, December 12, 2002 - 09:22 am: |
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thats the nicest rear bumper I have seen yet great job!
someone e-mail a link of it to rugged rover
great finish work!!!! |
Dave_Lucas (Dave_Lucas)
| | Posted on Thursday, December 12, 2002 - 11:12 am: |
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Rans,
I wish I could, I love building stuff like this. But in reality I think it is something I will have to keep as a hobby for now, someday I hope to retire and have a small fabrication shop but in the mean time I will just keep making projects for fellow enthusiasts and learning.
Musky,
 Thank you, for the glowing reveiw.
Greg, Garrett, thanks for the compliments, |
Greg Davis (Gregdavis)
| | Posted on Thursday, December 12, 2002 - 11:22 am: |
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Dave, smart move in keeping it as a hobby. Once you take the plunge and go into production, it takes on a whole nother dimension! Definitely takes the "fun" out of it. Believe me, I know. |
Rans (Rans)
| | Posted on Thursday, December 12, 2002 - 11:27 am: |
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I hear that Dave!!
Gregs bumper is nice too!
I need a bumper dammit, been trying to talk John at RTE into manufacturing one...maybe one of you guys wants to join up with John??
Anyway Dave, if you find yourself with an extra D2 bumper looking for a home, we can talk price! |
Mike Holmes (Myktoolbox)
| | Posted on Thursday, December 12, 2002 - 11:28 am: |
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" I have promised to build a few for other DII and DI owners here in Colorado as long as they would help me build it"
a few? and i thought i was special  sniff sniff. |
Dave_Lucas (Dave_Lucas)
| | Posted on Thursday, December 12, 2002 - 12:07 pm: |
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Sorry Mike,
But you are the first one on the list if that helps, but since you are going boarding I may sneak in one or two others while I am off for two weeks at Christmas. |
Axel Haakonsen (Axel)
| | Posted on Thursday, December 12, 2002 - 12:40 pm: |
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Dave:
Very nice job, indeed! You did an excelent job of matching the bumper to the lines of the truck, it looks very professional! |
Sean Butler-Lee (Seanblee)
| | Posted on Thursday, December 12, 2002 - 04:28 pm: |
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Well, I'm impressed! Looks very nice indeed, good job! |
Dave_Lucas (Dave_Lucas)
| | Posted on Thursday, December 12, 2002 - 08:45 pm: |
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Greg, that is what I think I am going to do, keep it as a hobby and enjoy building a few here and there for friends/other enthusiasts that would appreciate and use them.
Rans,
I will let you know if one just happens to appear in the shop There is a good chance of that since this one was my practice piece, now I am going to build another one.
Ax, Sean, thanks |
Shawn Peterson
| | Posted on Thursday, December 12, 2002 - 09:14 pm: |
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Dave
the shop picture shows the shackles connected using a black allen bolt ( 8.5 mm ? )and finish pictures shows hex, were the allens temp or did you switch for some reason. The reason I ask is I used the allen in place of the hex that came with my adventure rack but noticed after just a week they showed surface rust, did you experience the same. |
Dave_Lucas (Dave_Lucas)
| | Posted on Friday, December 13, 2002 - 12:25 am: |
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Shawn,
They were just used while I was fitting the parts, they were 12 mm plain uncoated steel and would rust rather quick in the salt laden roads of Colorado. |
ken knebusch (Charlotterover)
| | Posted on Friday, December 13, 2002 - 09:56 am: |
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SSSSSWEEEEEEEEEEEEEEEEEEEEEET!
I know what I want for Christmas! |
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