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Trooper II front bumper build

8K views 32 replies 12 participants last post by  NWTroop2 
#1 ·
Been building a bumper for the trooper this weekend. Last thing I've been working on is a hoop for it. Can't decide if I like the hoop. What do you guys think?
 

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#4 ·
I could see about drawing up plans. I just bought a piece of 3"x6" box tube and marked it up and started cutting, welding, and grinding. I was really happy with it until I put the hoop on it. I don't have a pipe bender so I miter cut the square tube with a portable band saw the best I could. I'm not sure if I'd like the hoop with round tube either though. Thanks for the opinions, and the compliments! That was a ton of work. First thing I've ever fabbed up other than an occasional bracket! Think I'll end up chopping the hoop off. It just has a few tack welds holding it in place now.
 
#5 ·
NWTroop2 said:
I just bought a piece of 3"x6" box tube and marked it up and started cutting, welding, and grinding.
OK, I see know. Did you relief cut it on the backside just outboard of the frame rails and pulled the ends back a little, then tapered them up to the outside? Pretty simple, if that's how you did it. At first glance I thought you'd welded together a bunch flat plates. Again, nice!

Mike
 
#6 ·
Yeah just a bunch of relief cuts to bend it to the shape I wanted and keep the original rounded edges. I should have taken more pictures but I'm not one for stopping before/after each step. Here's what I got for pictures of the process.

I also trimmed the front fenders a bit. They hung down below the bumper.

Sorry the pictures are out of order. Still trying to get that figured out.
 

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#10 ·
Picked up a Badlands 9000lb winch from Harbor Freight today. I thought I was going to mount it on top of the bumper but decided it wouldn't look so great that way. Anyways, I pulled the bumper and took some measurements and went after it again with the angle grinder and welder. Here's what I came up with.

It was a whole bunch more work, but I think it turned out good! Still need to mount the controller on the winch and get it fitted up and fully assembled.

Instead of saying "I" , I should be saying we. Myself and a friend of mine have been dreaming this up and working our butts off on it. It has been a good time though!
 

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#11 ·
Do you happen to have the original bumper?
 
#12 ·
Looking great.
 
#16 ·
Nice work.
 
#18 ·
gruff54 said:
Nice! Got a side shot of the rear bumper? How did you apply the Raptor Liner?

Mike
I purchased a kit off of Amazon that came with a "free" gun to spray it with. It can be applied with a roller too. I think you'd get a much smoother texture with a roller but I decided to spray to cover up some imperfections. It really did a great job at that.

I don't have a side shot of the rear bumper right now. I'm out of town for Thanksgiving. I'll put up side shots of both bumpers. I had to move the front bumper out a bit more to make room for the winch.

It was a fun project! I will be using Raptor Liner on the whole exterior and the floor.

More to come.....
 
#19 ·
Roller texture smoother than sprayed? I'd think it would be the other way 'round. Just went back and looked at your close-up pic. I guess the material sorta dries before it hits the surface and doesn't flow? Got a link to the kit you purchased?

Mike
 
#20 ·
Awesome job there, it looks beautiful! I wish I had a shop. I am looking for a winch bumper with the headlight guards (don't like the hoops) and can't find them for less than $1000.00
 
#21 ·
Awesome job on both bumpers.
 
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