DIY rear bumper build

[Johannes van die See]

Goeie werk Danie, lyk sommer baie sterk, ek sal seker eendag as ek die tyd het weer so projek aan pak, maar vir eers wil ek net eers daai boot van my kan haak en sleep, so eks dankbaar dat jy die projek begin het en my kan uit help met die sleep stang.

Ek volg jou draad, kan heel moontlik iets nuuts leer hier

[Nissan KingCab]

Next step: Cut 150mm x 50mm lipped channel and open holes for recovery points to fit through.

I used lipped channel because it already has the rounded edges and means a lot less work for the DIY person.
This picture shows the basic bumper with the recovery points and shackles fitted to get a first impression.

Bumper 1st image.jpg (175.92 KiB) Viewed 3636 times

I then cut a few wedges out of the lipped channel to form the bends.
After a few tag welds I removed the bumper to permanently weld everything together.

Bumper basic shape finished.jpg (118.45 KiB) Viewed 3636 times

[Nissan KingCab]

The biggest headache was to decide what to do with those funny corners and to get everything covered up.

The following three pictures will show the progress that was made.

1st The two pieces of lipped channel on top of each other (was lucky that 2 of them filled the gap)
2nd The manufacturing of something that looked half decent to cover the edge under the lights.
3rd Cutting of the steel to follow wheel arch.

Corner fabrication 1.jpg (362.19 KiB) Viewed 3613 times

Corner fabrication 2.jpg (391.36 KiB) Viewed 3613 times

Corner fabrication 3.jpg (346 KiB) Viewed 3613 times

[ricster]

While you are at it..... just something I have noticed is that the bottom corner sticks out quite far. It looks like the bottom of the lower lip channel is a bit higher than it would be if the plastic bumper was still there, but if the plastic knocked on the ground during some heavy 4x4'ing the plastic would give way ( usually causing the lights to pop out )

I would try look at shaping the bottom, or chamfering the bottom of the lip channel to help prevent solid steel hitting ground should you get int a situation like that.

[ricster]

But I must say.... I like it a lot !!!.... nice work there !!!

[ricster]

The Groot trek coming up made me speed up my rear bumper build.

I will show my progress with photos (they can say more than a thousand words)

20mm Steel plate bolted to the chassis for the recovery points!

Bumper bracket.jpg

This next picture is the completed recovery bracket and is bolted to chassis as shown in previous picture and 2 x 12mm bolts through chassis where original towbar is mounted.

Bumper bracket complete.jpg

Have you got a template of that bracket? I would like to get 2 made up for when I make my back bumper

[Nissan KingCab]

Just to update the build and to satisfy Ricster!

I did cut out a wedge from the corners of the bumper to give more rounded look and improve ground clearance!

These two pictures were taken after cutting out about 30mm in the corner and tapering to the wheel and brackets.

Rear bumper trimming 1.jpg (243.18 KiB) Viewed 3603 times

Rear bumper trimming 2.jpg (288.9 KiB) Viewed 3603 times

[Nissan KingCab]

Ricster, here is a photo of the template.

It is drawn to scale on this card board, if you like I could make a copy of it and bring it along on the River Trip!

Bumper bracket template.jpg (248.16 KiB) Viewed 3600 times

[ricster]

Thanks mate !!!....

I can copy the measurements from here and draw it In CAD !!!.... Thanks

The angle you have done looks sweet !!!

[hugejp]

Would these templates work on my 2004 Y61 4.8???