Bumper fab project - pics inside

[anothernord]

I wanted to run JDM fogs on my outback. I also hated how low the bumper cover hung underneath. So I picked up a harbor freight welder, helmet, gloves, and some good flux-core wire and started cutting.

I cut out the black portion to get a feel of where to put the main support
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130522_162952_960-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130522_162952_960.jpg.html)

Next, I cut 2 1/4" plates to bolt to the stock beam supports, and welded in a nice bottom bar to protect the radiator support
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130627_171725_844-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130627_171725_844.jpg.html)

I ended up cutting off the black area of the bumper cover completely, then cutting and bending the main bar to roughly match the profile of the bumper cover.
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130629_194828_938-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130629_194828_938.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130629_195047_918-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130629_195047_918.jpg.html)

The two pieces going back toward the car go on the outside above the tow hooks, where I bolted them to the steel around the tow hooks.
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130701_195405_298-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130701_195405_298.jpg.html)

Starting to come together:
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130630_161758_782-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130630_161758_782.jpg.html)

For a first fab project, I was somewhat pleased with a few welds.
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130630_161808_928-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130630_161808_928.jpg.html)

Mocking up the fogs:
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130630_165753_68101-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130630_165753_68101.jpg.html)

Tabs for fog lights welded on:
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130720_184615_727-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130720_184615_727.jpg.html)

After a bit of grinding and wire-wheel action, it was ready for some rollbar/chassis paint.
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130720_150837_320-1.jpg (http://s131.photobucket.com/user/anothernord/media/Bumper/IMG_20130720_150837_320.jpg.html)

I will probably be doing some more work to make it even sturdier, but so far, it's one of my favorite projects. It has come in handy many, many times.

Cinnamon Pass, CO 12,000 ft
https://sl-i.net/FORUM/images/imported/2014/03/IMG_20130706_131053_761-1.jpg (http://s131.photobucket.com/user/anothernord/media/IMG_20130706_131053_761.jpg.html)

[Muse]

gonna put anything to protect the radiator/ A/C core from flying rocks?

[Garrison]

+1 for some steel mesh in the middle!

[foohfooh]

hey man thats sweet. maybe added some clearance too? add a plate to protect the vitals and youll look like those desert ford rangers.

[Dead91silvia]

Not bad at all! I think you should do steel or aluminum plate over the center bars. Just for when that pesky snow or those big rocks come about.

[legacygt4]

I like it! you might want to consider some protection for the JDM fogs, If you even come close to doing some of the stuff I do offroad their going to get clobbered

[grayguy]

Know any one with a 1/2, 3/4, or 1" dimple die? That'd make for a Sweet insert in the center

Sent from my SAMSUNG-SGH-I537 using Tapatalk

[Junkie]

What's the scoop off of?

I have a tube bumper on my 99 OBW, round tube. However, it replaces the entire front bumper and is bolted to a fairly well bent bumper support (and the core support)

[Dead91silvia]

What's the scoop off of?

I have a tube bumper on my 99 OBW, round tube. However, it replaces the entire front bumper and is bolted to a fairly well bent bumper support (and the core support)

Look in his sig...