School Project
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Freshman User
Joined: Oct 2004
Posts: 27
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From: Mont Vernon, NH
School Project
All right, here's my dilema. In order for me to graduate from high school this year, I need to complete a "senior project". This is when we choose any topic of our choice and learn about it. So I chose to make off road equipment for my truck. I would like to make a push bar for the front, (one that covers just the center of the truck, I'm not really a fan of the large wrap-around ones), and perhaps a one-step nerf bar. I would also like to build a light bar for the bed.
This project is going to be fun, but challenging as well. I will learn how to weld, and fabricate steel.
I would like to ask any of you off-roaders out there:
1. are there any specific worries i should wonder about if I go to attach custom equipment on my truck? (1998 F-150 Ex.Cab)
2. are there any materials that you guys would reccomend?
3. have any of you guys done something like this before?
4. any tips?
Thanks for everything guys!
This project is going to be fun, but challenging as well. I will learn how to weld, and fabricate steel.
I would like to ask any of you off-roaders out there:
1. are there any specific worries i should wonder about if I go to attach custom equipment on my truck? (1998 F-150 Ex.Cab)
2. are there any materials that you guys would reccomend?
3. have any of you guys done something like this before?
4. any tips?
Thanks for everything guys!
Posting Guru
Joined: Jan 2003
Posts: 1,162
Likes: 1
From: House Springs, MO
Don't put anything on that will hamper your ability to go wheelin or keep you from using your DD as a DD. And make DANG SURE to disconnect the negative battery cable when welding stuff on.
Use whatever is free and/or cheap that you can get your hands on. I-beam, channel, tubing, pipe, angle, conduit, PVC, cardboard...
Use whatever is free and/or cheap that you can get your hands on. I-beam, channel, tubing, pipe, angle, conduit, PVC, cardboard...
Post Fiend
Joined: Jul 2003
Posts: 11,945
Likes: 3
From: Spokane, WA
Originally Posted by momudder720
Use whatever is free and/or cheap that you can get your hands on. I-beam, channel, tubing, pipe, angle, conduit, PVC, cardboard...
Sorry Mudder, couldn't help myself.
Posting Guru
Joined: Dec 2003
Posts: 1,391
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From: South Central Boise
I would suggest to make sure your attchment points are strong and solid. Do a good job and don't cut corners. Since it is your truck you want it to look nice too. Practice welding for a day or so and you will have a good idea of your skills. Rent a welding book from the library. Also, make sure you have all of your safety equipment to weld. Go with recycled metals. I have built a few bumpers and little odds and ends. Not complicated, just take you time. Good luck. Post some pics when you finish.
Posting Guru
Joined: Jan 2003
Posts: 1,162
Likes: 1
From: House Springs, MO
Hey, I had a swinger Busch beer box as a water-shield on my air cleaner before I got inventive with the rivet gun and some tin, so in a pinch, whatever work will indeed work.
Don't forget the zip ties and baling wire.
Hey Ivan, did you ever spring for the 60 tubes of JB Weld to stiffen up the push bar?
Don't forget the zip ties and baling wire.
Hey Ivan, did you ever spring for the 60 tubes of JB Weld to stiffen up the push bar?
Post Fiend
Joined: Jul 2003
Posts: 11,945
Likes: 3
From: Spokane, WA
Originally Posted by momudder720
Hey Ivan, did you ever spring for the 60 tubes of JB Weld to stiffen up the push bar?
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New User
Joined: Mar 2004
Posts: 7
Likes: 0
Just a thought... If you haven't yet you may want to do some careful searching on the internet or in catalogs (perhaps LMC truck if they go new enough for a '98) and look at the mounting points/hardware they use for nerf bars and such. Or perhaps check out a friends truck. Knowing how to attach items to the frame should ease your work and give you a starting place for dimensions. I'm thinking more specifically of the nerf bars. Good luck.
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Lead Driver
Joined: May 2000
Posts: 9,236
Likes: 12
From: Senoia, GA
a word to the wise....on the newer trucks especially, NEVER weld to the frame! with car manufacturers getting inventive and creative they started using different alloys back in the late 80's early 90's and began making frames with a mixture of 2 different metals for extra strength and better corrosion resistance. the problem is that it isn't standard mild steel like you would be used to welding on if you welded and can act up. also welding *can* create weak spots in your frame which could lead to some bad stuff!
also on other thing.... find a buddy with a welder and mess around with it for several hours or a couple of days. you can never be too good! burn up some scrap metal.
for the light bar you could prolly snag a roll bar from an old heep sitting in a j-yard close by or something to that effect.
-cutts-
also on other thing.... find a buddy with a welder and mess around with it for several hours or a couple of days. you can never be too good! burn up some scrap metal.
for the light bar you could prolly snag a roll bar from an old heep sitting in a j-yard close by or something to that effect.
-cutts-
Posting Guru
Joined: Dec 2003
Posts: 2,155
Likes: 3
From: Centerville, Iowa
98 F150? I don't know...The Nerf bars may be ok, but the light bar and bull bar I think I'd want to stick with a built one. Redneckin it is for older trucks and beaters. Course..that's just me.
Light bar would be nice. Poor me and my Flareside bed though. =(
Light bar would be nice. Poor me and my Flareside bed though. =(
Lead Driver
Joined: Aug 2004
Posts: 5,326
Likes: 18
From: Gilbert
Daystar makes a pretty nice light bar on the front end. Maybe you can try and duplicate something like that?
Here's the one they sell for the f-150:
http://www.daystarproducts.com/html/...tegory=Bumpers
The F250 one looks pretty stout. If you liked that design better, you might be able to incorporate the two together:
http://www.daystarproducts.com/html/...tegory=Bumpers
I'm sure if you searched around on the web, you could find some better pics that'll show some good mounting points. Good luck!
Here's the one they sell for the f-150:
http://www.daystarproducts.com/html/...tegory=Bumpers
The F250 one looks pretty stout. If you liked that design better, you might be able to incorporate the two together:
http://www.daystarproducts.com/html/...tegory=Bumpers
I'm sure if you searched around on the web, you could find some better pics that'll show some good mounting points. Good luck!
Posting Guru
Joined: Feb 2002
Posts: 2,404
Likes: 3
From: Cleveland, WI USA
If you really want a challenge, build an interior roll cage. LOTS of bends and calculations.
For the bed mounted roll bar, make one that bolts to the frame and not to the wheel wells.
For the light bar, I actually used galvanized electrical conduit. But, welding galvanized metal (I've learned) gives off poisonous gasses. People have been known to die from inhaling them. No reason you couldn't use thin wall tubing or even square stock.
I'd also like to ditto the scrap steel comment. That's all I use, and most of it cost me a six-pack here and there.
Good luck,
Kevin K.
For the bed mounted roll bar, make one that bolts to the frame and not to the wheel wells.
For the light bar, I actually used galvanized electrical conduit. But, welding galvanized metal (I've learned) gives off poisonous gasses. People have been known to die from inhaling them. No reason you couldn't use thin wall tubing or even square stock.
I'd also like to ditto the scrap steel comment. That's all I use, and most of it cost me a six-pack here and there.
Good luck,
Kevin K.
Elder User
Joined: Apr 2004
Posts: 650
Likes: 0
I agree totally with the used steel idea- prices on new stuff is outrageous. If you surf your local salvage yard you might even find components(brush guards, nerf bars, etc) from other vehicles that you could adapt to yours with just fabricated mounts. If you will be using a MIG welder I highly recomend grinding off the rust or paint where you will be welding it- I know a few people that believe just turning up the power on the welder is a proper alternative to clean metal- they still have nasty looking welds with poor penetration. ARC welding is more tolerant of contaminates on the metal, but cleaning it off is still a good habit to get into. Just out of curiosity, how much is everybody else paying by the pound for their "used" steel- I am currently paying .15
Posting Guru
Joined: Jan 2003
Posts: 1,162
Likes: 1
From: House Springs, MO
The jackass welding shop by me (both are usually drunk by noon and playing horseshoes and BBQ'ing by 4) just got done charging me $.50 a lb for a busted dump truck axle. Maybe it was because he thought I was some preppie a-hole 'cuz I wore my work clothes in there (khaki's and a polo), but I might take him a fifth of Tennessee's finest to smooth things out next time I go in there. And make DANG sure to be by BEFORE 4.30 and be wearing my dirty-work clothes.
