As some of you may recall, I was going to eventually fabricate a front bumper for my F350 crewcab.

Anyway, "eventually" arrived yesterday, and I started the assembly process. I was "forced" to do so immediately because I was pulled over for not having a bumper on my truck the other day, which was due to the bumper literally falling off a week prior. Inspecting the bumper, it became apparent as to why it fell off... the prior owner attached it using WIRE TIES!

I'm just glad no one got hurt when the bumper committed suicide on the highway. Anyway...

I wanted the industrial look of bumpers I see on commercial trucks, tow trucks specifically. So, essentially the front bumper will be 1/4" plate from the outside of the frame rails either side, with "wings" angled back from there, and a side piece that goes under the front fenders. Very simple, some basic triangulation, nothing terribly complicated. I sorta cut to fit as I went along, actually


Anyway, first picture... mounting of the angle iron into the frame holes normally used for snowplow mounts. I figured if these holes can support a heavy plow as it pushes heavy wet snow and sometimes hit curbs and rocks, its good enough for my new bumper. Plus using longer angle iron allows me to rest the bumper on the frame rails, supporting the front with my legs, and put a bolt in so I can get out from under it. Its going to be heavy




Now that the angle iron is bolted on, level, and adjusted to the same distance from the radiator support, I can tack on the front 1/4" plate.





The two wings have been added...




Next is to plasma cut out the wheel well area on the pieces that extend back next to the fenders, weld those on, then plasma cut out the diamond plate top, weld that on... then take the entire thing off, plasma cut the hole for the winch rollers in between the frame rails, make the winch subframe, cut out the driving light holes towards the bottom and box those out, grind, sand, prime and paint.

For driving lights, I have two choices sitting on the "spare parts" shelf. Two 6x8" isuzu trooper headlights, which are nice and flat as one choice, the other being 89 caprice headlights. I have the adjustment mechanisms for both and a section of the radiator supports so I can adjust the angles and not blind everyone. I'm leaning towards the caprice lights only because they are wider, yet lower profile. Though I guess either would work.

You might notice that the bumper is close to the ground, its actually 16" in height, which is 4" lower than stock. I was going to make the bumper 12" in height, then make a fiberglass skirt underneath to reduce airflow under the truck, but then decided since I had the steel why not just make the steel bumper go lower. More intimidating looking Anyway, I can always plasma cut it shorter if I really want to. Since there still is 6"+ of clearance, and I'm not lowering or lifting the truck, its fine.