Project Front bumper..

[The Patrolman]

I've done some scribbling and finally got around to making a template up to check some dimensions:thumb2
I've only done half as the other will be a mirror when CAD'd up for the Laserman:thumb2

This a trial for a flat pack easy to build bumper design. once the main shape is easily foldable by hand and weldable at home I may take a few orders.

I plan on having it lasered out of 3mm Mild Steel with slots cut along the bend lines to make it easy and then just run the mig around the joints and paint:nenau

[Lazy-Ferret]

Interesting idea. Will it also be winch compatible?

sent from my phone, sorry for any typo's.

[The Patrolman]

This is just concept stage for a low cost solution. once the mounting points and stiffness of the general assembly are proven I can start playin with the shape and various attachments.

Spot mountings / recovery points and high lift jack points.

I am also incorporating the steering guard underneath, bracing it back and up to the chassis and cross tube.

[elty001]

Must be catching this bumper making caper:nenau
I've got a little project for a terrano winch bumper over the winter.

[Banshee]

Must be catching this bumper making caper:nenau
I've got a little project for a terrano winch bumper over the winter.

Will be watching with great expectations!!!!

[Fez_uk]

Should look good, I guess it's going to be somewhere in between the original and a winch bumper?

[The Patrolman]

Most of the original Y60 Troll front bumpers are now hanging:(
This should be a fairly nondescript replacement.
I have extended the ends out about 2" to allow the new arch extensions to meet up nicely and possibly mount some arch protectors.
I want to bring the chassis mounts up through the top of the bumper to allow a tube to run across the top of the flat section.
I should have some designs drawn up early this week and the fisrt unit within a week or two.:rolleyes:

[The Patrolman]

After a week on the sick with Man Flu the only thing I have to show for it is a trial bumper design:thumb2
this is the base 3d model and the outer stiffeners need trimming as they do not need to protrude past the main bumper:augie
Getting there:thumb2

[The Patrolman]

And the flat packed 3mm steel origami version looks like this:naughty

[Fez_uk]

ooh CAD, very posh.

Is this a front bumper? Not sure if I like the top rail thing?

[The Patrolman]

Been doing the CAD thing for years..

this is more of an experiment to see how easy it is to bend and assemble and how stiff it is - hopefully it will be hot off the LASER this week:thumb2

[Fez_uk]

still posh, down here we use cardboard and a ruler ha

Would love to learn how to use cad.

[elty001]

just had it installed on my pc at work but not had a chance to really play with it yet.

[The Patrolman]

still posh, down here we use cardboard and a ruler ha

Would love to learn how to use cad.

See #1. Cardboard:clap

[spinna]

Looking good. I will have to keep an eye on this thread:thumb2

[The Patrolman]

Finally got my bumper Laser cut from 3mm:thumb2
I need to reduce the joint tabs by about 75% as it is proving very stiff to bend.:augie
I will take a cutting disc to this one to get it in to shape and see what it looks like this weekend:thumb2

[jims-terrano]

Wow, I really admire someone with the skills to do this. It'll be great to see the finished bumper.

[The Patrolman]

Bent and tacked into shape. quite pleased sofar:thumb2

[The Patrolman]

A few minor adjustments to make:rolleyes:

[The Patrolman]

And Another for good measure i know you like the photos:thumb2

[AlexD333]

That's looking tasty, when is the fit? :naughty

[The Patrolman]

Trial fit tomorrow in the daylight:thumb2

[R1cho]

looking very nice, is this something you will be able to do for the terrano/maverick aswell or are you just keeping it for you trol users?

[AlexD333]

looking very nice, is this something you will be able to do for the terrano/maverick aswell or are you just keeping it for you trol users?

Oooh :naughty

[The Patrolman]

follow the procedure from cardboard to MDF to Steel.
I have a friendly fabricator with Laser machines. if you can draw what you want I wiil give it a go:thumb2

[Sweety]

Looks great:thumbs

[The Patrolman]

Found another one:thumb2

[firebobby]

looking very nice, is this something you will be able to do for the terrano/maverick aswell or are you just keeping it for you trol users?

You could always get one like Alex's.......then again :augie

Very impressed with the work so far, looks great :thumb2

[johnb5177]

Very tidy bit of fabrication, looks great, even better when coated up and fitted.....:thumb2

[The Patrolman]

Trial fitting today:thumb2

[The Patrolman]

from the side

[The Patrolman]

look almost how I expected:D

[The Patrolman]

Doesn't stick out too much from the front , just enough to get a tube across when the chassis mounting plates are fitted next week..

[The Patrolman]

Just a few minor mods to make for a production run model.
I'll make the bend slots about 1.5mm from 3mm to reduce the amount of weld required.
I need to reduce the width of the joint tabs as they were too thick to bend by hand. down to about 5mm from 20mm i think..
Tidy the side return up to remove the sharp point.
The spacings of the panels need aligning by about 1.5mm to allow for bending.

And that should do it for the main part.

[R1cho]

very cool, excellent look, you might want to move them stands though they will drag on speed bumps :lol

[The Patrolman]

Derr....:nenau

Did you not spot the holes all the way up them... They are adjustable:doh

:thumb2

[elty001]

looking good:thumb2

[AlexD333]

Monster, loving it :sly

[spinna]

That's looking brilliant:thumb2

[firebobby]

Very neat job, I think your troll needs a wash and polish though ;)

[makeitfit]

Very neat job, I think your troll needs a wash and polish though ;)
Looks way too clean to me :lol

http://i667.photobucket.com/albums/vv36/daudwpsyn/IMG_20131027_153634_zpsaftzftup.jpg (http://s667.photobucket.com/user/daudwpsyn/media/IMG_20131027_153634_zpsaftzftup.jpg.html)

[The Patrolman]

It has rained

[Ianinessex]

Looks way too clean to me :lol

http://i667.photobucket.com/albums/vv36/daudwpsyn/IMG_20131027_153634_zpsaftzftup.jpg (http://s667.photobucket.com/user/daudwpsyn/media/IMG_20131027_153634_zpsaftzftup.jpg.html)

You appear to have missed getting mud on the OS headlight. Go back and try again. :naughty:clap:augie

[AlexD333]

You appear to have missed getting mud on the OS headlight. Go back and try again. :naughty:clap:augie

Hah well spotted sir.

[makeitfit]

Nah, that's just a Trol wink ;)

[The Patrolman]

Just looking for ideas:nenau

[trophymick]

Just looking for ideas:nenau

Alex is your man.:thumb2

[AlexD333]

Well my bumper is pretty extreme and quite marmite with a lot of folk.

Something like makeitfit's front trol bumper is pretty sexy, perhaps a bigger version of that would be beefy :naughty

[The Patrolman]

Yea! another update. we now have the 10mm plate mountings hot off the laser machine:thumb2
osf uses the original M14 nissan bolts.

[The Patrolman]

nsf uses new 10mm tapped plates for M16 bolts.

[The Patrolman]

and now with both:augie

[The Patrolman]

We then fit the trial bumper with the outer stiffeners. it is a bit wonkey but I need the revised bumper before getting the welder out again

[The Patrolman]

just needs the 40mm tube through the top set of holes and the ones beneath those are for shackles if needed:thumb2

[The Patrolman]

with a bit of luck bumper mk2 will be available on friday:D

[The Patrolman]

3 months later the next sheet of 3mm Steel is on the laser bed:thumb2

[The Patrolman]

A few minutes later Hot out of the Laser machine:thumb2

[The Patrolman]

A few bends to get it in the car and 4 hr drive home.
will post a few assembly pics n updates soon but hope this one's good. I then have a base template to start mods on:thumb2

[iansjones]

That is coming on really well and looks great.

[The Patrolman]

First few bends:thumb2

[The Patrolman]

one corner somewhere near:thumb2

[The Patrolman]

Got a bit more done today:thumb2

[The Patrolman]

A bit more welding and Voila:thumb2

[The Patrolman]

Not a bad fit if I do say so myself:lol

Just need to take it off and seam weld it and fit the two bracing tubes ready for galvanising and powder coating:thumb2

[don simon]

Looks good.

[elty001]

Looking good :thumb2
I've got my front bumper laser cut, need to get it folded and tacked up for trial fitting .
Also got the rear one in the same stage.

[The Patrolman]

Cool. I went for the origami approach as I do not have easy a cess to a bender...

[Barrbeast]

Looking good :thumb2

[The Patrolman]

Blagged a bit of tube today:thumb2

[The Patrolman]

Tomorrow I will be mostly......."Welding!"

[solarman216]

you mean that you did not have the tube before you welded those 4 brackets, and they all lined up perfect? Rick

[johnb5177]

P P P P P P......:thumb2

[The Patrolman]

you mean that you did not have the tube before you welded those 4 brackets, and they all lined up perfect? Rick

You sound suprised:nenau

[solarman216]

You sound suprised:nenau

I am very much so, I have been welding for very many years and know only too well how much a weld can pull a bracket about, so yes I am amazed, Rick

[elty001]

I like that :thumb2
Not sure weather or not to put a tube section of mine when it eventually gets folded :lol

[The Patrolman]

I am very much so, I have been welding for very many years and know only too well how much a weld can pull a bracket about, so yes I am amazed, Rick

I checked it by eye when it was tacked up so it should be ok:thumb2

[The Patrolman]

You sound suprised:nenau

To be honest Rick, I didn't even contemplate the idea that it wouldn't line up:doh

Lady luck was with me on this one!

I should've known better with a HND in fabrication and Welding Engineering:doh

[spinna]

That's coming along nicely

Sent from my SM-G900F using Tapatalk

[The Patrolman]

weldin' went ok:thumb2

[The Patrolman]

I decided against getting it galvanised n powder coated.

Good old fashioned paint, and lots of it, Quick drying Chassis enamel.

[The Patrolman]

And stick it back on:clap

[The Patrolman]

I'll wait for this coat of paint to harden and sand off the lumps then a coat of black should do nicely...

[elty001]

The man from delmonte say yes :thumb2

[Fez_uk]

Looks good, not sure about the bar on top though

[Sweety]

The man from delmonte say yes :thumb2

+1 looks ace:thumbs

[The Patrolman]

Thanks Sweety:D
It will look better in black!

[Sweety]

Thanks Sweety:D
It will look better in black!

That it will:thumb2 only one thing I would try & do if it was mine is to find a bung or cap for the ends of the tube to keep water & mud out

[emjaybee]

I assumed the tube on the top of the bumper was for displaying the scalps of other 4x4's that are rescued.

:D

[The Patrolman]

That it will:thumb2 only one thing I would try & do if it was mine is to find a bung or cap for the ends of the tube to keep water & mud out

I am thinking about welding some vertical bits of tube to the ends:nenau I think they would be intimately useful for mounting poles for washing lines tarps etc

Or some removable bungs:thumb2

[Daemo]

thats a great looking bumper, not sure about the top bar idea but we all like different things... great design and well executed.

[The Patrolman]

Thanks for the comments.
The aim of this little project is to get something that can be flat packed for shipping, cheap (ish) and can be put together easily by club members.
As most Troll owners will know,by now most front bumpers are rotten and replacements are thin on the ground.
I folded this by hand welded it my self an painted it with a rough stick.

There are still a few mods to make to make mounting easier but the main design and dimensions are pretty good.

Now I have the basic cad drawing minor mods are easy to implement this one is about 8 wider than standard to alow for the tyres:augie

anyone interested in one similar please let me know.

[jims-terrano]

I am thinking about welding some vertical bits of tube to the ends:nenau I think they would be intimately useful for mounting poles for washing lines tarps etc

Or some removable bungs:thumb2

Brilliant project and as Sweety says when painted black will be spot on. Just one thing will any vertical bits however small be legal? No idea personally but Im sure you understand my point. Like the idea though for mounting things on.

[The Patrolman]

Well after a minor alteration to the front bumper going up hollingscough:eek:
the bumper has been tapped back into shape with a 14lb sledge hammer and glued in a few more locations with the trusty mig.
there were a few contributing factors that lead to is initial demise.
I had ground back a bit too much of the weld on the front edges and not welded a few places that allowed it to crease where it should have held.
Oh and the repeated bashing into a rock didn't help too much:doh
Also there was only one bolt on the near side to the chassis which allowed a bit of pivoting.

I have now fitted the captive bolt plate into the chassis leg:thumb2

Before

[The Patrolman]

A bitt of super sticky tape:thumb2

[The Patrolman]

the tape is pressure sensitive so a bit of a nip up with the bolts inplace

[The Patrolman]

And Voila:thumb2
Hel well and stayed there whilst I re attached the bumper:thumb2

[The Patrolman]

Bumper looking a bit straighter now:thumb2

[The Patrolman]

and from the side:thumb2
Its a little wobbly in places but a good test and I now know which bits need tweeking and adjusting:thumb2

[elty001]

Looking good mate :thumb2
That said rock put a nice dint in my 5mm thick front bash plate, it don't take any prisoners :lol

[The Patrolman]

just need more Amps in the welding Dept:thumbs