Custom Rear Bumper

Total cost in material $80, weight 70lbs

Supplies:

• 2 x 4 x 1/4 channel
• 2 x 1 x 1/8 channel
• 1 x 1 x 1/8 square stock
• 4 x 7 x 5/16 flat stock
• 1/4 flat stock
• 2 D Rings

To start I cut off the trailer hitch and most of the stock bumper mounting supports. Next the 1/4 inch flat stock was used to cap the frame ends and the recovery rings were mounted directly to the frame for strength. Brackets were then added to the 2 x 4 channel so it could be bolted to the frame with four 1/2 grade 8 bolts. The same 2 x 4 x 1/4 channel was used on the sides to add strength at the corners. Next, the 2 x 1 x 1/8 channel was used to finish the side and give the bumper a sleeker look. At that point I trimmed the rear quarter to about 1/8 in above the bumper to allow for trim to be added to give the side a more finished look. Then the 1 x 1 x 1/8 square stock was used to secure the bumper to the frame right behind the tire. This was also bolted on so the bumper can be removed if necessary. And last using L brackets the fender was reattached to the sheet metal slightly higher than before to keep the fender secure.

The good thing about this bumper is it is very strong and very cheap to build. Also, its much shorter and higher than a stock D1 bumper. Total time to build the bumper was about 20hrs. from start to finish. You have to cut a bunch of metal off to make this bumper work so if you are squeamish about cutting you might not want to try this one.