It really wasn't that hard to make the cardboard templates. Just get enough of it! The only real hard part for making the pattern was the bottom flange because when you bend it, you have double angles, not just one angle like the front peices. What I did for the bottom flange is get a square peice of cardboard(lets say 4"x5") put it flush with the front, bottom peice and bend it back the the angle you want. Keep one side straight, and then mark where the other side is hitting on the next peice. Sounds confusing, but it makes easy sense when you do it. Make the top profile first, then go from there. I will have to get my scanner hooked up to get the patterns on, or at least the measurements. Lights are inset 4 1/2" flood tractor lights. used plumbers threaded pipe(all I could find laying around) set it in, marked how much I had to take off so they were pointing straight


I cant remember the exact measurements, but the front peice was 42", first angled front peice was 11", then 4, 4, and 11 on the corner.

I ran out of time in shop class because I wanted to take it home, herculine and mount everything up during our spring break, which was 9 days long so I wasnt able to do all the things I would have liked to do. I wasnt going to put the shackles on until that friday night. Yes, I am not going to pull anyone out, thats what the hitch is for. I only pulled people out from the snow witht eh shackles. I am going to get hooks for the frame.

I have about 60 hours into it, A LOT OF GRINDING. I welded everything up with the 220 welder.

 

Nice Job the bumper turned out great, but yeah unfortunately no one really makes bumpers for the older model Fords... We get requests all the time...

 

You wanna make some cash Josh?

I'd love a Bumper like that for my 1993 Bronco!
How'd ya like a commisioned job to build another one?

 

Nice work. I have been thinking about one for my 88. I will build one myself instead of paying over $1000 for one.

 

Great work. It has to feel way more rewarding when you look at your truck and see you project then seeing what could be a cruise around Hawaii for a week. I found a homemade front bumper/brush guard at a parts yard for 15 bucks. I love it, and it doesn't look half a good as yours. I used an undercoating spray to paint it, but the hurculiner looks better. post pictures of the rear bumper when you get it done. I like!

 

very, very nice. needs to be copied!!

 

Like everyone else said- Great job - keep it up the bumper looks great.
I feel everyone should be creative to make their own parts. It takes time to do projects like yours, but the reward is worth it. Saving money is what I like to do too!

 

was the herculiner sprayed on or painted on?

 

That is a very nice job ! ! ! !
Great Job

 

The herculiner is rolled on. I have heard negative reports of this product, and most of it is because of poor prepping. Like anything, prepping is the most important if you want to the product to stick. I grinded everywhere I could in the rear and all in the front. I sandblasted all the welds on the inside because some were rusty, oxidized ect. Then I did two scrub downs with a green scrubber and acetone. The only spot I dont think I really prepped well was the inset light tubing. Because of this, its starting to peel. But unlike Line-X, all I have to do is prep the area and roll on where it needs it. My buddy bought a truck where the owner sprayed the frame with Line-X. He did not prep, maybe a wire brush. I find Line X forms to a hard, rigid material, but Herculiner is flexible, which could be good and bad.

Heres a picture a few months later. I have stood all over this bumper while working on my custom intake, including the tubing..





crane celevis



I just graduated highschool so I dont have a lot of money. I find Herculiner a good enough product, as long as you do the prep work. I did my rocker panels, door jam, tailgate, rear bumper and interior floor also. I grinded or sandblasted everything down to bare metal, and acetone scrub.









Again, its not Line-X. If I were to put myself in situations where I needed the additional durability of it, I would. I dont rock climb, run into trees or buildings though.

 

I'm with you on that one.
Line-X is a great product, but Herculiner is almost just as good, and for the price you can not beat it. I'd take it over Rhino liner any day.

The truck is looking really good, nice work on the bumpers.
I'd bet all this was done with just one gallon of herculiner, with some left.....

 

what prep process did you use on the rockers. it looks great!

 

I dont remember exactly how much, but with 1 1/2 gallons, I did two coats on the interior, 2 coats on both front and rear bumpers, one coat on cowl scoop and 2 coats on the rockers(and underside) and tailgate

I would say 1/4 gallon for the front bumper.

I took my 4 1/2" angle grinder and ground the rockers down to bare metal. Took me a good 3 hours, but it was well worth it. I took the schools air sander and sanded the tailgate down in 30 mintues tops. I used the trim as a reference line.

As far as herculining, the first coat is real thin, acting like a primer. The second coat you can cake on.

 

Well the bumpers still look great!. Any chance in the future of herculining the whole truck? I have seen a few like this. some on the herculiner website. Also i like the center console. Keep up the good work Josh.

 

Slowly, but surely, you are getting that truck looking better and better.

You gave me some sweet
ideas to aplpy to my truck, thanks!