Author Topic: SquareD Part 6 Bumpers, Winches, wiring, lights, assembly (Read 453245 times)

Flyin6 · « **Reply #550 on:** May 18, 2015, 08:42:30 PM »

It fits!

Flyin6 · « **Reply #551 on:** May 18, 2015, 08:43:36 PM »

I'll either stand it up or lean it back some...undecided at the moment

Flyin6 · « **Reply #552 on:** May 18, 2015, 08:45:22 PM »

So next I wanted to address the gap beneath the roller fairhead and the brush guard uprights

Flyin6 · « **Reply #553 on:** May 18, 2015, 08:47:06 PM »

I am angling everything so that obstacles are swept to one side or the other. You can see here there are two big open mouths that would hold onto stuff and direct it under the center of the truck, not what I want

Flyin6 · « **Reply #554 on:** May 18, 2015, 08:54:42 PM »

The deflector will push trees and Kias to either side and it serves to really strengthen up that frontal area which now approaches 1/2" think laminated steel on the bottom side

Flyin6 · « **Reply #555 on:** May 18, 2015, 08:55:43 PM »

I applied the appropriate amount of sparks and smoke and came up with this

Flyin6 · « **Reply #556 on:** May 18, 2015, 08:56:38 PM »

The whole fairhead projection is super strong now and not so bad looking either

Flyin6 · « **Reply #557 on:** May 18, 2015, 08:57:42 PM »

Next I was hunting for a spot to mount these:

Flyin6 · « **Reply #558 on:** May 18, 2015, 08:58:57 PM »

I think I'll have to mount them about 1.5" proud to the bumper face on a couple thick sections of rectangle steel tubing

Flyin6 · « **Reply #559 on:** May 18, 2015, 09:01:32 PM »

All 4 of those bumper LED lights came in as well. I will cut them into the bumper after I figure out where those mammoth tie down rings mount which have yet to come in. Heck, I might mount all 4, who knows?

I'll likely tie them into the high beams so when I decide to light up the world, you could see me from orbit

Flyin6 · « **Reply #560 on:** May 18, 2015, 09:03:42 PM »

And that is the SOB (State of the build) on build day 257

Mission continues...

JR · « **Reply #561 on:** May 18, 2015, 11:31:49 PM »

Those lights are a little smaller than I thought, but I like em!

I would angle anything forward so as to snag it. Isn't the idea is to have em slide off?

BobbyB · « **Reply #562 on:** May 19, 2015, 02:45:05 AM »

For the lights, in my opinion, 2 closer to the center of the bumper, and the other to towards the other edges. That way, you'll get a wider area of ground/obstacles illuminated when using them.

cudakidd53 · « **Reply #563 on:** May 19, 2015, 07:10:56 AM »

Proposed warp avoidance method:

What if you welded a straight (bit larger) steel beam across the inside of the bumper horns that put them in outward pressure? Then weld up the bumper alternating sides until completion and hammering each fresh weld. The hammering method is something I've seen my father use to successfully weld cast iron which is notorious for cracking along the weld as it cools. Then, just take your blue light saber and remove the brace(s) and you might have a warp free bumper?

Flyin6 · « **Reply #564 on:** May 19, 2015, 07:57:46 AM »

Quote from: cudakidd53 on May 19, 2015, 07:10:56 AM

Proposed warp avoidance method:

What if you welded a straight (bit larger) steel beam across the inside of the bumper horns that put them in outward pressure? Then weld up the bumper alternating sides until completion and hammering each fresh weld. The hammering method is something I've seen my father use to successfully weld cast iron which is notorious for cracking along the weld as it cools. Then, just take your blue light saber and remove the brace(s) and you might have a warp free bumper?

Well, Mike, you are getting ahead of me here, but today, I was planning to get some rectangle steel tubing and weld it on the underside spanning from the box center section which is mostly welded up now outward to the winds, and fix a second 1/4" plate to the back side of the main bash plate for a landing pad. It won't be able to move inward/outward, but it might still be able to twist...

Flyin6 · « **Reply #565 on:** May 19, 2015, 08:02:26 AM »

Quote from: BobbyB on May 19, 2015, 02:45:05 AM

For the lights, in my opinion, 2 closer to the center of the bumper, and the other to towards the other edges. That way, you'll get a wider area of ground/obstacles illuminated when using them.

They will be fired up with the high beams
High beams are used when there is no approaching traffic
So who cares how they are aimed with regard to on coming drivers?
Check
So maybe two pointing sorts forward
and two in one of the outward plates all outward angled to give more of a wide angled view...
Was thinking about that and other options as well

EL TATE · « **Reply #566 on:** May 19, 2015, 12:55:05 PM »

How about an adjustable cross member at the corners, like a tie rod? lateral strength at the corners increased to resist angled impact, threaded tie rod end adjusters to keep the corners from warping in. it's my experience that the "memory" of heated steel is pretty hard to forget. you could make infinite adjustments this way.

Dawg25385 · « **Reply #567 on:** May 19, 2015, 01:23:50 PM »

That bumper is looking sweet Don. I like those recessed LED's too, and the weld on bull rings. Going to be a menacing bumper for sure!

KensAuto · « **Reply #568 on:** May 19, 2015, 03:12:56 PM »

I did pretty much what mike was talking about except for forcing it outwards.....I wasn't sure about how much it would need. When I was done, it was sucked in 1/4" on each side.....had I known at the time, I would've stretched it 1/2".

Flyin6 · « **Reply #569 on:** May 19, 2015, 10:05:20 PM »

Quote from: KensAuto on May 19, 2015, 03:12:56 PM

I did pretty much what mike was talking about except for forcing it outwards.....I wasn't sure about how much it would need. When I was done, it was sucked in 1/4" on each side.....had I known at the time, I would've stretched it 1/2".

I had that experience after boxing the frame. Remember, the bottom of the frame pulled inward maybe 1/2" on each side.
I'll do something even if it's wrong!

KensAuto · « **Reply #570 on:** May 19, 2015, 10:22:42 PM »

At least you can say that you did somethin' no matter the outcome!

Flyin6 · « **Reply #571 on:** May 20, 2015, 07:38:15 PM »

Speaking of did something, I did something today.

The mail man delivered the 1" D-rings so I knew they were getting glued up

Here they are, I purchased 4 of them

Flyin6 · « **Reply #572 on:** May 20, 2015, 07:39:41 PM »

I'll be using these new welding gloves which still have all the fingers and no chew marks

Flyin6 · « **Reply #573 on:** May 20, 2015, 07:40:45 PM »

So, right off the start I welded those on and know what? That box never saw any shelf time!

Flyin6 · « **Reply #574 on:** May 20, 2015, 07:42:35 PM »

Next up were the clevis mounts

I needed to stand them off a bit to clear the uprights, so I created this spacing assembly

Flyin6 · « **Reply #575 on:** May 20, 2015, 07:44:03 PM »

Here is where the cleaned up stand-offs will be fitted:

Flyin6 · « **Reply #576 on:** May 20, 2015, 07:45:41 PM »

They were welded inside and out and onto that bottom plate as well. Should be strong enough

Flyin6 · « **Reply #577 on:** May 20, 2015, 07:47:12 PM »

The clevis mount was first welded to the back plate. I used a lot of heat and fast wire speed. There's a lot of metal joining the two parts!

Flyin6 · « **Reply #578 on:** May 20, 2015, 07:51:49 PM »

Here's the final:

Flyin6 · « **Reply #579 on:** May 20, 2015, 07:54:24 PM »

Next up, It was time to find a place to mount the winch control module.

But first I disassembled it so I could remove the factory bolts and replace with my longer stainless screws so I could more easily and sturdily mount it

Flyin6 · « **Reply #580 on:** May 20, 2015, 07:57:15 PM »

Then make a template, cut the stock, finish it, drill it and weld it to the upright

Flyin6 · « **Reply #581 on:** May 20, 2015, 07:58:25 PM »

And just like that, the module was mounted.

Flyin6 · « **Reply #582 on:** May 20, 2015, 08:01:08 PM »

Had enough time remaining to address the strengthening of the bumper wings. To do this I will use some 2" square high strength steel tubing and cut it in to fit all the contours and tie the winch box directly to the wing making a triangle out of the flying parts

Flyin6 · « **Reply #583 on:** May 20, 2015, 08:02:54 PM »

The first cuts were made and I had this piece which was already tucking up very nicely, maintaining the high ground clearance built into this bumper design

Flyin6 · « **Reply #584 on:** May 20, 2015, 08:04:50 PM »

THe areas of fitting tie together either side of that 1/4" Curved section that is yet to be joined to the neighboring reinforcement. Don't worry, it will!

Flyin6 · « **Reply #585 on:** May 20, 2015, 08:05:54 PM »

After some more tweaking and fitting, both sides were ready to be welded in

Flyin6 · « **Reply #586 on:** May 20, 2015, 08:07:47 PM »

View before and after

Flyin6 · « **Reply #587 on:** May 20, 2015, 08:10:25 PM »

I know, ugly weld...Had a large opening to fill in and know what? I don't care, will cover it with something and it can spend the next 50 years being strong like ox!

So you can see the stiffeners tucked up nicely and even though that bumper is largely still just tacked together, it just got very rigid

Flyin6 · « **Reply #588 on:** May 20, 2015, 08:13:34 PM »

That's all the time I had today, but I feel like that was a good point to stop.

Now all I have left to fab is the tubing hoops, then pull the bumper and add in all the inside bracing, weld it, then paint or coat it

So ends build day 258

Nate · « **Reply #589 on:** May 20, 2015, 08:52:18 PM »

nice work

Atkinsmatt · « **Reply #590 on:** May 20, 2015, 08:53:59 PM »

That bumper is coming along very nice.

Flyin6 · « **Reply #591 on:** May 20, 2015, 08:58:01 PM »

Danka!

JR · « **Reply #592 on:** May 20, 2015, 11:31:24 PM »

It does look good, nice work.

Looking at those D ring mounts do you think the will hold when sideways force is applied? Thinking they are close to the mount point, but welded indirectly via plates and surface loads. I'm sure the welds are fine, but I thought D ring mounts would be stronger if attached to the mount plate itself.

The ones I got are about 6 inches long for welding right to the mount through bumper.

Pulley · « **Reply #593 on:** May 20, 2015, 11:48:11 PM »

Looking good, makes me wish I had the creative mind to fab up something like that haha.

cudakidd53 · « **Reply #594 on:** May 21, 2015, 06:58:46 AM »

Very nice work there Don- good news is you'll need to

Start it up!

to remove the bumper for final welding and finishing!

Flyin6 · « **Reply #595 on:** May 21, 2015, 08:21:56 AM »

Quote from: JR on May 20, 2015, 11:31:24 PM

It does look good, nice work.

Looking at those D ring mounts do you think the will hold when sideways force is applied? Thinking they are close to the mount point, but welded indirectly via plates and surface loads. I'm sure the welds are fine, but I thought D ring mounts would be stronger if attached to the mount plate itself.

The ones I got are about 6 inches long for welding right to the mount through bumper.

JR,
I think that boxed 3/16" and 1/4" plate is plenty strong enough, but a lot of that has to do with the quality of the welds, which I'd say is adequate, and the boxing plan for the backside which has only started. There will be some work back there.

Having preflighted helicopter tail booms and what I could see of the wings on my jets, what I learned of structure I am applying in the things I build. I am building this thing to foremost reisit a head on force such as me ramming through a substantial road block. But I am also trying to build in torsional rigidity which would be needed if, say, I jacked the front up by a bumper wing.

Actually, I'd like to run a bar aft to grab the frame somewhere and one from the wing up to grab something, but there is nothing, so I just have to build a strong semi-monocoque structure.

Flyin6 · « **Reply #596 on:** May 21, 2015, 08:30:12 AM »

Quote from: Pulley on May 20, 2015, 11:48:11 PM

Looking good, makes me wish I had the creative mind to fab up something like that haha.

I think a creative mind is one of my gifts. My head is always buzzing with ideas like this...
But I also believe we are our greatest limiting factor. Saying I can't puts a self imposed limit on yourself. Nope, I won't go that far so I can't. I learned to replace I can't with, "Now how can I get that done, what do I have to do?"

My boys know death and destruction is on them is they say "I can't" in my presence. They have to do pushups and situps or clean toilets or something like that if I ever catch them saying "I can't"

Just sharing here. You can be creative, just gotta entertain the possibility!

Another short story...in my book...

I remember the day I was fishing with my dad, a former bomber pilot himself. The lake was buzzed by a low flying F-4 Phantom. I looked at that craft, 60 feet long of demonic death from the clouds moving along at probably 500mph. I watched that thing sow thunder in the valley then tear the air apart in a vertical climb. I watched it like I was witnessing the second coming.

Dad asked if I'd like to fly one of those. Me, fly, a pilot? No way, I could never do that. Well, I flew over 30 years and got into the most elite flying unit in the rotary wing world. You can do what you want, just gotta go do it!

KensAuto · « **Reply #597 on:** May 21, 2015, 10:41:11 AM »

Nice bumper. Me likey.
Kinda MadMaxish, in a good way.

JR · « **Reply #598 on:** May 21, 2015, 02:37:09 PM »

Don, I will er to your judgement on that, it is your bumper. It was just something I wanted to say,

Getting to it is one of my issues. Sometimes I think it will be a pain and it not and building goes great.

Picked up a set of run flats (new type) and my springs yesterday and built a shelf in the old compressor shed for all the darn parts!!

Build on and sometimes disregard this this DOT, just sometimes ???

Higher Caliber · « **Reply #599 on:** May 21, 2015, 10:07:29 PM »

I say after you weld it solid you don't grind anything and let it sit in the rain and rust slightly, then clear coat it!