front bumper for Masda pickup

[Frank S]

The front bumper will serve as a means to store the tow bar inside of it and also there will be other storage areas inside the bumper for related safety equipment such as safety cables tow lights and a connector cord to plug into the tow vehicle

Cut out to be the door hiding the tow bar

bumper clamped in place

tow bar folded in stored position

Will have to add small cut outs so the door can be closed while tow bar is in use

Nothing beats my plasma cutter for these projects

Even though I may never finish doing the mods to my folding break it works perfectly
For bending the bumper parts shown is a plate which will serve as one of the mounts and a back for the built in storage compartment

[DIYer]

Thanks Frank S! We've added your Pickup Bumper to our Autobody category,
as well as to your builder page: Frank S's Homemade Tools. Your receipt:

Pickup Bumper by Frank S

tags: autobody

[Frank S]

Update for the bumper
This is my plasma machine, In the construction of this bumper I used just about every cutting tool imaginable
Plasma, Oxyacetylene torch angle grinders, band saws, die grinders, belt sander Drill press, lathe, and a pipe cutter. About the only things I didn't use were the chop saw and the mill

fitting the grill guard

the door measurement is done via 2 captured bolts passing through the verticals

from inside the bumper there is a hole to access the nut that keeps the bolts from falling out when the door is open also should the need ever arise the bolts can be replaced

this is the mating nut welded inside the door hinge /lock channels when the door is closed you have to know to look behind the grill guard or you might not know that the door opens

A little etching primer

Black bumper ready to be re mounted

[Frank S]

the bumper is now on the truck with the tow bar mounted inside
http://www.homemadetools.net/forum/tow-bar-mount-68720




In case anyone is wondering the push bars on the door serve multiple purposes
the hinges on the bottom and a means to secure the door

[12bolts]

Nice work Frank. What happened to the cutouts for the tow bar when "in use"? Or did you use a different work around?

[Frank S]

Nice work Frank. What happened to the cutouts for the tow bar when "in use"? Or did you use a different work around?

Click on the first picture to blow it up and you will see the face of the bumper just hinges open while towing the pickup there is no need to close the face so there are no cutouts

[KustomsbyKent]

Frank S,
Nice looking bumper!
Any pics of your tubing bender?

On the bumper cover that stays hinged open while towing, any concerns about it bouncing & banging with it hanging open?

Do you have to do anything special to the vehicle's drivetrain before you bumper tow it?

Thanks
Kent

[Frank S]

No real concerns about bouncing or banging a simple bungee or tarp strap would cure that it it happened to be the case
As for the drive train it has a 5 speed manual transmission. I was initially concerned Since the newer manual transmissions with OD lace up differently. than the old Borg Warner and Muncie types. So while I had the transmission apart on the bench after completely going through it with new cluster shaft bearing kit seals 2 of the synchronizes and the input shaft I also replace the plastic oiling trough that lubes the front bearings. With the top still off and the proper grade of ATF in it I rotated the tail shaft to watch the gear splash. That was when I noticed they had finally engineered oil traps into these transmissions to keep oil on the bearings even if they are left sitting for months or years without being used there would still be oil on the bearings even the center shaft needle rollers have a small cup made in to the shaft
As soon as the tail shaft is rotated there is gear splash and as long as the fluid level is kept at least half full to spec there is lubrication.
the modern constant mesh manual transmissions have both advantages and disadvantages
the advantage is every thing spins all the time. the disadvantage is everything spins all the time.
By having everything spinning all the time there is constant lubrication everywhere by having everything spinning all the time there is an almost negligible amount of drag on the tow vehicle. If I were planning on towing this or any other vehicle for 100,000's miles behind a motor home I would install an electric drive line disconnect at the diff. And treat it the same as if it had an automatic I would recommend the disconnect even for 4 wheel drives if I were going to pull one for long distances frequently behind an RV

[Scotsman Hosie]

Wow! That's quite a piece of design engineering, Frank S. Thought through, and carefully fitted. And beautiful buttoned up too.

[ranald]

LOVELY work Frank. Will the extra weight affect the wear on suspension etc?