This is quite a project and I do not do metal fabrication, but would like to learn, what I am attemping is a custom bumper for my 1994 Mazda B-4000 or as most people know it a 1994 Ford Ranger. Made off Fords assembly line, the only thing changed was the hood and grill, everything else is ford standard parts. I have designed a bumper, front and rear in CADD and would like to put the front one together, and then eventually get to the rear. The design includes 4 holes for factory lights, as well as a winch mount, brush gaurd, 2 8" Rally light Brackets, and a 2" reciever. It is a very large bumper and I think it is very do-able and will make a great off-road bumper. I am looking for it to be constructed out of 8" or 10" C Channel Steel probally 1/4 inch steel, although I am not set in ways and will take idea's from anybody. I am not looking at spending tons of money, this truck is my pride and joy and I want the best for it, at cost, but I am willing, my sweat, tears, and blood to make it happen. Don't think I want it done for me, I learn quick and have mechinical skill. I also have vast knowledge in other area's where I may be able to teach others a trick or 2. Everything is clearly labeled on the drawling but there are not too many measurements. As far as I could measure the bumper is 64" in total length, and needs to be 12" in width, including the side flares you will see in the drawling. It is quite a bumper, and I would expect it to be a weekend project. I would like to per say, build it on the truck so it fits, and is not to wide or to narrow when we try to mount it. This project is really being done so I can mount 2 rally lights, and a winch, as well as give a firm place for recovery, by the D Style Clasps I plan to use, and also dress up my truck!!

The file is a PDF, since it should be universal... right?, I guess!!

I live in the Reading, PA Area and would like to find help locally and give a hand with this bumper, anyone who is willing to help I will glady give plans to. I also plan to submit this design if I like it to a company like smittybuilt or a custom fabricator for production, kinda like the rough and tough Ford bumpers, so if I can do that, we will make an even split between everbody on the settlement. Of course, I'd have to remove some items from the design, I wana be the only truck sporting this one like it is :)

Thanks Guys, I am a newby but I hope these plans raise an eyebrow and someone feels its do-able.

Let me know, Im willing to pay for all materials and labor, I'm just not a billionare, just another crazy redneck... well not a good redneck since I can't weld.

Thanks Again!
- Brian

Bumper PDF

 

if you could drive to Virginia, i bet member "solodos" could build you a bumper... [and he is cheaper than a custom fab shop]

jeff does very good work...

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you basically wanna build something like this:



with holes for lights? and a winch mount?

 

Yep, you pretty much got it right there, I'll drive pretty far for good workmanship! Just a few minor changes but that bumper looks fantastic!

 

You may want to consider something smaller than 1/4" channel for the bumper. C channel steel is extremely strong and 1/4" will probably be overkill not to mention extremely heavy.

A couple things to consider when making the bumper are the location of the grill, the shape of the grill, and the overall shape of the front end. Looking at the front of my truck (yours is newer and may be different) the grill sits lower than the lights so if your bumper is straight across, it will leave gaps under the headlights. I was going to use 9" channel under the lights and 8" under the grill which will allow for a straight bottom edge but the top will somewhat follow the shape of the truck. Some filler pieces would be welded in to make an angle where the different size pieces meet and make it look decent. The other thing this does is give you an opportunity to make the bumper conform to the front of the truck when looking down at it since the front end has a decent curve. At the point where the pieces of channel are welded together, a slight miter cut would allow the bumper to angle back and follow the headlights better.

Also remember that the winch plate will need to be at least 7" deep so you're going to have to build the bumper to stick way out from the grill to make it all fit. The alternative is to have the tow hook mount torched off and mount the winch between the frame rails which moves a lot of weight back and takes some of the stress off the front end and allows you to move the bumper closer to the truck which again takes stress off the front suspension.

 

I would suggest building the bumper out of round tube for a frame and then skin it wil sheet metal. Or like teh bumper Christian posted use 4" piepe then skin it with sheet metal, that on was diamond plate.

C channel will be huge adn massive, thsu very heavy and it is pretty expensive. It will tweak before a framed bumper will.

If you wnat me to help you with it, shoot me a PM and we can talk about it.

 

Hey Guys,

Thanks for the quick response and great suggestions! Im new to the whole fabrication end and I know 1/4 inch steel would be heavy but your probally right that it would bog my front end down alot. so maybe a lighter gauge of C channel. The reason I chose C Channel is because I really like the look, and a nice wide sturdy bumper is always nice when you tap something, by accident of course , I have also seen another truck, same year make and model with a similuar bumper and love it! About the bumper height, 9" would be fine, straight accross, the bumper I currently have (stock) is flat, so I assume it should be no problem to make a flat one, but that was a great concern I didn't think about. Another thing is that dang winch, nobody has a great spot to mount it but it becomes a very nessicary tool, what I would like is to have it mounted where I have it to allow accessibility, and looks. Unfortunately... it will probally be in the way, but if I do not like it there, I have the 2" reciever hitch, that can be made to hold it and then it would also be removable, and able to be attached to the 2" reciever in the rear. So Maybe that is the better of the 2 options. Let me know what ya think.

I need Idea's for What Gauge C channel would be strong, but "light"

Also I believe you guys saw the 2nd diagram on there, it looks like a C turned sideways, that is the upright view of the bumper, as if you rolled the first diagram forward. That will give you the angles and the approach I wanted to take on how it contours the truck.

Let me know what you all think!

Thanks!
- Brian

 

im gunna use 3/16" thick c channel for mine. that is plenty strong for a bumper.

 

That does seem pretty strong, the design of the C channel also gives it strength, weight is always a concern, I don't want it to be on the ground , are you putting a 2 inch reciever and tow hooks in your bumper?

- Brian

 

If you are talking about true C-Channel, it doesn't come in 12" x 1/4" thick...
It is called out by height x pounds per foot. Here is a helpful website.
http://www.efunda.com/math/areas/Rol...elChannels.cfm
12" C-Channel would be overkill. You would rip apart the front end of your truck
before your bumper would bend. I would suggest forming 7 Ga. (3/16") steel to
make a channel. This way you could bend the material in different directions on
the same piece. Just make sure to use gussets near the winch & receiver mounts.

 

I thank you for the information, but originally I was talking about 9" high and 1/4 inch thick C Channel, everybody has pointed out that 3/16 would be plenty and I do agree. the 1/2 inch thick would be the tubular Brush gaurd on the top, which would be hollow steel tube just bent into a C and then placed on the bumper at an outward angle. But thanks much for that website, its very helpful if I can figure it out

After reading up on it, I would probally use something like C9 × 20 but maybe using flat stock and bending it into a C would be better, that is hefter than I thought it would be and seems to be almost 1/2 an I Beam instead of Flat Stock bent into a C. Great Idea and I may just have to use that, it would deffinately save some weight, but still hold the strength. I believe I will already have to re-enforce the 2 inch reciever with some kind of plate or bracket to make sure it is attached to the frame as securely as possible. Worst thing that could go wrong would be I am getting towed out and they tow out my bumper , That would hurt!!

Thanks for the idea, its really starting to come together how we should make this so it performs to the best of its ability, I want the best of all worlds, the recovery points (for recovery, you know I'm gonna "git-r-stuck") and strength for the winch, as well as inpact into a solid object (not something I am gonna try, but it happens) as well as having a good looking bumper but not wrecking the stance of my truck because of it. I think we have come up with some idea's and they are good ones. If anyone is instrested in manufacturing something like this, let me know and can take a weekend trip to your location, and we can work on it all weekend, I think it should only take a day. But I will not let you stuck, I'm a good hard worker, and a good thinker!!

So Let me know if you are instrested, and we can work out something for payment and a good time and place to do it!

Thanks Again!
- Brian