Eventually I am going to make a set of bumpers for my 2000 f250. I've built a few bumpers before for87-91 series, and am a fabricator by trade so the actual build wont be a problem, but its the idea thats going to take a while and would like your input.

This truck is a daily driver, and the most abuse it will see would be pulling, tugging and maybe a bump here and there, but not running into rocks. That being said, I am thinking of making the main part of the bumper 1/4". This part would be from framerail to framerail. The rest would be 10ga permitting how big the the peice it going to be. If theres a lot of seams and angles, 10ga should be fine. if its bigger than say 1 sq ft, then 7 ga. I dont see the point in lugging around the extra weight. If you get in a severe crash to buckle the bumper, theres probably bigger problems.

I would also like to run a "portable" winch. Again I dont want to be lugging around the extra 150lbs when it will rarely be used. I would like to get at least a 12k and put it on a crate that will go into a hitch receiver that will be put on the bumper itself. obviously I would have to make some kind of quick connect for power and ground. I will also run 0 ga to the back of the truck so I can use the winch back there as needed.(my plans on the rear bumper is integrating a 3-5k winch for winching boats onto trailers, logs, atvs onto trailers...)
Hitch receiver is a must. I put one on the bumper for my 88 and it comes handy, especially backing up trailers in tight quarters, I can only imgaine how nice it will be for these trucks with huge turning radius.
Maybe an integrated plug for the block heater so nothing dangling.

4 integrated lights under the headlights, maybe some small running lights in the middle. I would also like to put a small light inside the bumper to illuminate the ground around front of the tires?

Integrate something for the oil or trans cooler?

I hate prerunner bumpers, but I do like the looks for tubular grille guards, but I will have to consider workability under the hood.

What I usually do is build the whole bumper out of cardboard. Then I can take it all apart and shear, plas or torch each peice. possibly get a flat pattern and bend them.

It will probably be quite a while before I get to building it, so share any ideas or thoughts so i don't say "I should have put this on there"

-Josh

 

I am gonna do something like Ranch Hand or Buckstop does. I need two, one for a 350 and one for a 550. Did the rears already, they are both flat beds. Look into the new 3/4" led's available from places like AW towing catalog. They are bright, cool, low amp and nearly indestructable. Could be used to illuminate the front wheels as stated.


Ironwood

 

I fabbed a couple differnt styles for front and back.
Front on a 97 I had we built the main body out of 2-3'' schedule 80 pipes that we stacked on top of each other.It was all skirted and trimmed out with 1/4'' tread plate.Cut 2-6'' rectangular holes in the very front of those two pipes for air flow to the radiator.Fabbed the grill guard out of 1'' schedule 80 pipes which protected the grill and lights and was welded to the 3'' main bumper.....Sorry no pics.

Back bumpers were made from 4'' schedule 80 pipe.We cut two of the 4'' pipes at a 22 degree angle and welded them to the main pipe to angle down for the drop.Welded 3/8'' plate for the trailer ball mounting surface.This was all skirted and trimmed with 1/4'' tread plate.
Reciever hitch was mounted/welded beloe the 3/8'' plate.

 

How did the sch40 pipe bend? How tight? Usually we build handrail out of sch40 but nothing under 10ft diameter.
I started building the cardboard template today and took me all day to get about halfway done. I am trying to make all the parts so i can get them into autocad and have them cut on the cnc plasma table and bent rather than a weld joint. It would be nice to have them on the computer if i ever decide to build another. These front ends are a real challenge to make everything flow with the multiple contours and at the same time have it totally original. I have about 6 hours into the design and will probably another 10 before i get it the way i want it. I will take some pictures so soon as it starts to represent a bumper.

 

Keep us updated and post up some pictures!

There is a member here (Bergerson I think) Who made his own bumper, I got to check it out in person at RRW and it was really nice

 

Subscribing!

 

This one uses 3x5 tubing (0.25" wall?? - its heavy...) and plate.




$1050 for those of us who can't build our own............
http://www.advancedmfg.net/bumpers.htm

 

I saw a custom rear bumper on a dually one time that had storage bins for chains/binders/etc. Coolest bumper I've ever seen!!!

 

I like the storage idea. I was going to cut a hole in the bed and put a box where the spare tire would sit(since i have oversized tires) on my 88. Or cutting a rectangle in the rocker and weld a box for chains ect.
Waltdog, do you have an 05 grille? It seems like the 05 dip lower than the first gen. Also, what size lights are you running? I have just enough room for a 6" and a 4"(they will be in the same spot as yours)

 

Yep 2005 grill . The lights are 4" and 6" PIAA 510 and 540 respectively

 

What about some steps incase you need to get up into the engine bay. The only way i can get into mine is by jumping on the tire, lol,

 

On my bumper for the 88 the top was flat which made a okay step but snow and ice would sit on it all winter, especially beind the lights and grille guard. On this one i am doing a 2" lip, with 1" sitting under. This way it will give is a nice line and will make it look like the bumper was made for the truck. Since there is very little flex in the frame i can have 1\4" gap if i wanted to. The rest will be angled
You could make a step to pin into the hitch reciver. Maybe make it swivel

 

I made up the cardboard template last weekend. This weekend I am going to take all the peices and make them into another bumper to make sure all the measurements are good and will fit tight. have pictures on the digital camera but am unable to upload to the computer at this time. Heres a picture with my phone



The front, or main section of the bumper looks pretty boring, but as I mentioned there will be two celvis tabs and a hitch receiver. I also want to cut out "powerstroke" or "international" and backlight it. Also some vents will be added.

A few other ideas i am looking for is the quick connect for a winch. I would like to run a portable winch so permanet wires going to the bumper, then a quick connect from the winch to there. Probably a switch from the cab so those two wires going to the bumper arent alway hot. Is there any kind of sealed box (like an outdoor outlet) or something similar for this setup?

 

NAPA has heavy 12volt plugs, usually blue or grey.

 

I finally got around to drawing all my parts on autocad during my 15min breaks. Cut them out on the cnc plasma table. Keep in mind this is the first bumper I have made for these trucks so theres going to be a few things that wont work as planned, and some things changing





3/8 plate with slots.



1" plate with 1 5/16" hole, originally it was a 7/8, but the celvis looked too dinky so i will need to get some big celvis. the hole is centered with the frame.


mounted the main section of the bumper. leveled plum and tack





it might be hard to see, but the bottom part of the bumper has vents. the holes on the front are only on one side because I figured thats where I will mount the license plate, winch quick connect and block heater plug. I did have to move the shackle plates up an inch so it was centered on the frame, hence having to cut an inch out of the main part of the bumper.

Some things I noticed was the frame had a lot of difference. In the picture, its tight against the grille but there was about 3/16 difference height wise on the frame. I could also take a pipe clamp and move the frame in and out with little effort. My buddies f350 has a factory tube crossmember, do the f250s not?

I will be running the portable winch, hence the hole for the hitch receiver. I will be running a tube from the hitch tube to the shackle plate.