Part 1 of 2 due to the amount of images

Well, since a bunch of you have asked about how I made the bumper. I uploaded some of the pics that I took while I made it.
I new I wanted to run PIAA 520 fogs with the ion crystal lens.....mainly due to their looks, but they also provide a decent amount of light.

So, I was searching for some tubing or pipe that I could use to french them into the front bumper. Couldn't find anything big enough at any of the steel places around here....and calling around other big tubing place they wanted like $43 a foot for some of the stuff that I could have used. Well, my dad mentioned some of the pipe that they used where he was a GM for 23 yrs at a fence manufacturing place. Since he left they've gone bankrupt and bought out by another company, but I still have three cousins that work there. So I called them up and had one of them bring some scrap pieces home. It ended up working out perfect for the light....it's 6.625" O.D. 0.250" wall pipe that is used for industrial gates. So I lined it up with the bumper to try and figure out the proper angle to cut the pipe. Marked it, and took it to my cousin's work to use their bandsaw to make the cut. The mounts ended up looking like this:


So now that I had the mounts made and ready to go, it was time to swap a XL bumper off of one of our work trucks onto my SD. Once I had swapped it I traced the lines where I was going to cut out for the lights, and where I was going to cut the lower corner off to provide better tire clearance:



Then one night after work I made the cuts. I used a jigsaw since I don't have a plasma cutter or anything like that.

 

Part 2 of 2 due to the amount of images

Another evening after work I welded in the mounts inside and outside, used a grinder on the outside, and shot some spray paint to keep it from rusting while I was finishing it up till I had time to take it to get painted:


After I finished welding on the tabs for the lights to bolt to etc.. I took it to my buddy's body shop. They welded the lip back on where I cut off the lower corner and prepped and painted the bumper:



And of course how it looks today now that I've added the painted grille shell, the black billet grille, '05 Harley Davidson Headlamps, etc..:


Hope this give you a good idea of what all is involved.
Let me know if there are any questions.

 

That is a great looking bumper! Very good work.

 

PERFORMANCE RED

Thanks for the compliment.

 

Dang it, DC - it's Christmas!!! I got so many irons in the fire that it'll be Easter before I can do a proper pull-out...and here you are with all these mod pics flaring up!


Great job, btw...

 

Big Orn
Yeah, I picked a good time to start posting again on the forums and uploading pics huh?

Thanks for the compliment

 

Cool...I really like the looks of those lights in the bumper!

Thanks

 

Dan,

Your killing me man! That looks soooo freakin good dude!

 

The only thing I need to see now is a post called "Show Your Heat Extractor Hood!" LOL That would push me over the edge LOL

 

Bronco532
Thanks for the compliment


Kevin,
Dude, if you would just get that bumper shipped to me yours would be under way bro . Hmm.....maybe I should go cut the pipe for your bumper today

Well, I have the camera with me....but the trucks all covered in road salt, otherwise I'd take a whole bunch of high res. pics of the hood an email them to you

 

......that makes it look like a Dodge from the front.

All kidding aside, that is a nice piece of work. Looks very nice.

 

....the Dodge lights are smaller and clear though

There's a guy on another site that bought the Dodge fog lamp kit and put it on his truck how I did mine...

Thanks for the compliment