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Poll

How black do I go on the front end? Raptor Liner in my possession.

Just bumper.
9 (81.8%)
Whole front end.
0 (0%)
Bumper and Chrome.
2 (18.2%)

Total Members Voted: 11

Author Topic: Sam's 2006 LBZ front bumper  (Read 20275 times)

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Offline Sammconn

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Sam's 2006 LBZ front bumper
« on: May 19, 2015, 12:08:57 AM »
Just a teaser.

Spent the long weekend with the blue light sabre, grinders, welder and even some snow.
I need to upload the pics from my phone, so with any luck I'll be at them in the morning.

I can't say any of the aftermarket bumpers really turn my crank, they all stick out too far for my liking. So what's to come will show a very low profile, as my buddy called it, Urban Assault Bumper build. I too am an owner of HF 12000# Badlands winch, and am shoe horning it into a bumper that is probably only a couple inches deeper than the stocker.

Sorry, it's late, my back hurts and I am something tuckered out.

Yeah excuses excuses I know... 8)
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline JR

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Re: Sam's 2006 LBZ front bumper
« Reply #1 on: May 19, 2015, 12:14:29 AM »
You know, Ive had a new winch ready bumper in my garage now for a year. As nice as it is, it does go WAY out and from the rear looks flimsy and is why I haven't mounted it. I was going to gusset it up, just never seem to get to it.

Looking forward to your pictures. Just priced a 4x6x250 wall tube for the "base" of my spartan bumpers.
Retired LEO  Lifetime NRA+  Outcast in Calif

"The tree of liberty must be refreshed from time to time with the blood of patriots and tyrants"

Thomas Jefferson

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #2 on: May 19, 2015, 12:15:33 AM »
Added a finish poll in.
I figure I need the week to get it to the finishing point.
Still a lot to do.

I have 200 miles of the ugliest dirt road you can imagine that I cross to get out of the bush. I'm tied with how I want to do it and each has its merit.

So we'll see what yall think. Poll expires in 7 days.
Thanks for your .02.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #3 on: May 19, 2015, 12:17:04 AM »
Just priced a 4x6x250 wall tube for the "base" of my spartan bumpers.
That is a serious chunk of steel!
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Online Flyin6

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Re: Sam's 2006 LBZ front bumper
« Reply #4 on: May 19, 2015, 07:20:26 AM »
I went with bed liner black, depending on what bedliner.
Do not use epoxy...it gets hard and scratches easily. So far the Raptor liner is the best product I have found that one can spray. Having said that, it scratches so I almost voted to just paint the bumper and touchup as necessary because touchup on a 2-part urethane is a complicated and expensive proposition.
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Offline EL TATE

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Re: Sam's 2006 LBZ front bumper
« Reply #5 on: May 19, 2015, 10:18:03 AM »
2nd on the Raptor liner. Nylon bristle brush, soap and water, get someone else to do it, and your bumper will look about the same 10 years later as it did day one ;)
Husband, Father, Gear guy, Patriot.

Online KensAuto

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Re: Sam's 2006 LBZ front bumper
« Reply #6 on: May 19, 2015, 10:44:41 AM »
Can't go wrong with Mr Raptor Liner, especially with 2 coats....rocks will just bounce off of it.
« Last Edit: May 19, 2015, 10:45:16 AM by KensAuto »

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #7 on: May 19, 2015, 02:38:05 PM »
So I awoke to this to start out my build...



Started on mounts, 3 x 3 x 3/16 wall.



Pulled out tha blue light sabre and had this.



Cleaned them up, transfer punched, drilled and tapped to use stock mount holes.



And now I have a platform to work off.

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #8 on: May 19, 2015, 03:19:51 PM »
Being my daily driver, and my only way out of here in the spring, I wanted to maintain the stock bumper mounts as long as I can.
Something about driving around without a bumper that the LEOs don't like.



While looking at Don's build up, I had an Ah Ha moment, the flat plate to build off was my mounting solution.
Starting point to mock up winch clearances.



Layed out to cut.



Cut out, winch holes added.

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #9 on: May 19, 2015, 03:23:30 PM »
Bent the ends up about 14 degrees or so, and test the fit again.



Was happy with the fit and proceded to start the roller fairlead plate.







And setting in front to get the idea...

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline JR

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Re: Sam's 2006 LBZ front bumper
« Reply #10 on: May 19, 2015, 03:47:46 PM »
Just sharpen those edge up and run something down!!
Retired LEO  Lifetime NRA+  Outcast in Calif

"The tree of liberty must be refreshed from time to time with the blood of patriots and tyrants"

Thomas Jefferson

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #11 on: May 19, 2015, 04:15:09 PM »
Well, we'll start off plumb.



Had some shackle points made up.
These turned out to be AR Plate, so they got scrapped, and mild steel made later.



I didn't do any templating at this point, just keeping the top level, all 1/4" plate thus far.



And that wrapped up day one.

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #12 on: May 19, 2015, 04:20:49 PM »
Test fit to have a look and come up with the next move.



Tried 40 degrees for the rake angle, sees to work.





Maintaining the stock-ish profile, I added on the lower 'wings'.

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #13 on: May 19, 2015, 04:25:40 PM »
Then completed the 1/4 plate lower vertical face.



In an effort to not warp everything all out of whack once done, I've elected to weld everything solid as I move along.
So far it's working, time will tell if it was right or not, and I'll regret it if I need to cut anything out to change.

Moving forward onto the raked back face, I've now switched to 3/16 plate.





I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #14 on: May 19, 2015, 04:29:02 PM »
Somewhere in the last few pics day two ended, and we are now into yesterday afternoon.
I have reached the point where eyeballing will no longer work.





Transferring into steel now.



I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #15 on: May 19, 2015, 04:31:13 PM »
And the last of this row all tacked in.



I clearly forgot to transfer a few last pics, but its all welded solid, and we'll see how it fits tonight.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Online Flyin6

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Re: Sam's 2006 LBZ front bumper
« Reply #16 on: May 19, 2015, 10:01:54 PM »
Good work

Reading this I'm having a deja-vu moment all over again!
Site owner    IS 6:8  Psalm 91 
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Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #17 on: May 19, 2015, 11:29:05 PM »
It's definitely trying...on the back...on the patience...well you understand.
Pushed on again tonight and have most of the welding done.

I have a dilemma, created by not wanting a fat lip bumper, I'm not sure what to do with the center portion. I've been in conversation with couple buddies and had suggestions to leave it open, hinge a lid, or extend the free spool handle. I'm scared of a hinged lid for a variety of reasons. Can't extend the free spool handle as it is beneath the grill. In these chats, had the idea of a 20 something inch light bar to fill and leave open in the rear for access to the handle. I was planning on two or four lights like Don and Ken have used, but with the real estate I now have, I am leaning to a pair of 7-8 inch bars if they can be found in a flush mount.
I'm open to thoughts and suggestions.
Will update some more pics tomorrow I hope.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #18 on: May 20, 2015, 07:48:48 AM »
So here is the test fit after adding most of the upper steel.







Everything stayed straight and it fits pretty good!
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #19 on: May 20, 2015, 07:52:37 AM »
This is the space i still need to address.



And here is the dilemma with the free spool handle.



I think I'm leaning to the light bar, but it is going to seem 'unfinished' with the hole.
Just so I could see, right aroung 4 1/2 inches from the grill.

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #20 on: May 20, 2015, 07:55:50 AM »
Finishing up the top edge.





Now I've got a whole lot of grinding to do.
I plan on a lower skirt swept back at a 45 degree or so angle.
I'm going to be putting a receiver on the bottom as well.
That will come once I clean up the welds and see where I want stuff.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Online Flyin6

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Re: Sam's 2006 LBZ front bumper
« Reply #21 on: May 20, 2015, 10:04:15 AM »
It's definitely trying...on the back...on the patience...well you understand.
Pushed on again tonight and have most of the welding done.

I have a dilemma, created by not wanting a fat lip bumper, I'm not sure what to do with the center portion. I've been in conversation with couple buddies and had suggestions to leave it open, hinge a lid, or extend the free spool handle. I'm scared of a hinged lid for a variety of reasons. Can't extend the free spool handle as it is beneath the grill. In these chats, had the idea of a 20 something inch light bar to fill and leave open in the rear for access to the handle. I was planning on two or four lights like Don and Ken have used, but with the real estate I now have, I am leaning to a pair of 7-8 inch bars if they can be found in a flush mount.
I'm open to thoughts and suggestions.
Will update some more pics tomorrow I hope.

This perhaps:

http://www.ruffstuffspecialties.com/catalog/R1863.html
Site owner    IS 6:8  Psalm 91 
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Offline JR

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Re: Sam's 2006 LBZ front bumper
« Reply #22 on: May 20, 2015, 01:34:12 PM »
I really like how the upper blends with the cab lines.

I say extend the handle but make the top bolt on so you can get to it with relative ease. Plus you may have to help the cable spooling clean after use and access is a must.

Good idea on the front receiver, but don't hang to much off the lower end (jmhi)

Are you going to reinforce the rear or box it in?   
Retired LEO  Lifetime NRA+  Outcast in Calif

"The tree of liberty must be refreshed from time to time with the blood of patriots and tyrants"

Thomas Jefferson

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #23 on: May 20, 2015, 02:06:21 PM »
I really like how the upper blends with the cab lines.

I say extend the handle but make the top bolt on so you can get to it with relative ease. Plus you may have to help the cable spooling clean after use and access is a must.

Good idea on the front receiver, but don't hang to much off the lower end (jmhi)

Are you going to reinforce the rear or box it in?
It was an adventure keeping it in line.
Turns out my weld it solid as I wen worked out for me.

Was talking with the guys at work this morning, the latest thought is to close it up flat to make a step of sorts.
I'll still have to extend the handle, but I completely forgot about a step.
Now with your mention of spooling issues, I may go flat, but bolt on for access.

The receiver will basically only be for pulling stuff onto the car hauler, not for a lot else.
As for the back side, I still plan on some gusset plates inside and a few other random reinforcements.
« Last Edit: May 20, 2015, 02:09:17 PM by Sammconn »
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #24 on: May 20, 2015, 02:07:25 PM »
It's definitely trying...on the back...on the patience...well you understand.
Pushed on again tonight and have most of the welding done.

I have a dilemma, created by not wanting a fat lip bumper, I'm not sure what to do with the center portion. I've been in conversation with couple buddies and had suggestions to leave it open, hinge a lid, or extend the free spool handle. I'm scared of a hinged lid for a variety of reasons. Can't extend the free spool handle as it is beneath the grill. In these chats, had the idea of a 20 something inch light bar to fill and leave open in the rear for access to the handle. I was planning on two or four lights like Don and Ken have used, but with the real estate I now have, I am leaning to a pair of 7-8 inch bars if they can be found in a flush mount.
I'm open to thoughts and suggestions.
Will update some more pics tomorrow I hope.

This perhaps:

http://www.ruffstuffspecialties.com/catalog/R1863.html

Yep! That would be what I'm after I think.
At least I know they're available, and can cut holes before I get to coatings.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #25 on: May 20, 2015, 02:11:35 PM »
Talking about finishing at work also.
Color matched Line-X came up.
I'm not at all familiar with how close they can get so I'm a little on the fence with that.

Added option 6, change your mind if you need to.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Online TexasRedNeck

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Re: Sam's 2006 LBZ front bumper
« Reply #26 on: May 21, 2015, 06:50:48 AM »
I voted painted because its much easier to touch up.  What ever you put up there will get damaged in some way or fade.  Paint is easy to touch up and keep looking good.  Liner will look good for a while then after a few years be a real hassle to re-do or touch up.
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

Joshua 6:20-24

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #27 on: May 22, 2015, 10:45:06 PM »
Well it's been a slow week on the bumper.
I'm building a cedar chest for one of my niece's graduation and it needs done soon.
I've been picking away at grinding the outside and fixing any voids that turn up.
While adding in some gusset plates I noticed that the cable was going to run on the lower roller all the time. I made up some 1" thick spacer plates to raise the whe winch.
Once I trial fit everything it became obvious that my free spool handle issue was no longer there. That inch put it above the plane of the open center portion.
I've since added in closures on the sides and flat plates to fix the cover to.
It will double as a step which I neglected to add in anywhere else.

Redneck, I believe I am going to start with paint for now. I'm not going to have time to do any bodywork to it at the moment so it's going to be a bit rough.
If I go with how the masses are voting it will end up with Raptor Liner on it. I don't have access to that here, and will have to pick up from the city.
It may turn out I like it and if that's the case I'll do it up right.
I need to have it on the truck when I head out next week to have an allignment done with the new heavier front end.

I have some updated pics to get posted up once I make time to sit.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #28 on: May 23, 2015, 10:05:18 PM »
So at the moment I'm waiting on the base coat to flash for 30 mins and then on with the clear. All I can say is I wish I had a bit more time to do the body work on it. It looks real sharp in paint, here's hoping that it does match. Will know in the morrow.
I'm going to get the pics up tonight I hope as it's not that late yet, and I only need a couple shots of clear.
Going to check on the ice after. We may have water this week, and if so the bumper will be done just in time.

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline JR

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Re: Sam's 2006 LBZ front bumper
« Reply #29 on: May 24, 2015, 02:12:48 PM »
Color match in regular paint or liner?

If the truck was red or something I think it would tacky, but silver should look good.
Retired LEO  Lifetime NRA+  Outcast in Calif

"The tree of liberty must be refreshed from time to time with the blood of patriots and tyrants"

Thomas Jefferson

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #30 on: May 25, 2015, 10:06:30 PM »
So I'm working off my phone at the moment. So we'll see how this goes and if it annoys me too much. Have no wifi where I'm staying so the puter is not working.

So I began the grinding process to clean things up for my initial option of paint.



I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Online Flyin6

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Re: Sam's 2006 LBZ front bumper
« Reply #31 on: May 25, 2015, 10:11:27 PM »
Looking good!
Site owner    IS 6:8  Psalm 91 
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Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #32 on: May 25, 2015, 10:11:48 PM »
Then a pre-positioning of the winch to check clearances with the new spaced blocks.





Now the drum is up in the window of the rollers, and should not run exclusively on the lower roller.
Chief, not sure if you had caught this or not. I can't take credit, a buddy was over looking at things and made me aware. Without the inch riser the cable would have run every foot on the lower roller.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #33 on: May 25, 2015, 10:19:39 PM »

And lookie here. The spacer fixed one of my other problems too!

Now the free spool handle is above the face plane and I can work with it.



The said spacer blocks.


I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #34 on: May 25, 2015, 10:23:44 PM »
Added in some gusset plates.



Permanizing the spacer blocks and the mounts.

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #35 on: May 25, 2015, 10:29:58 PM »
While I was at this I needed to look after another problem I had. My factory hitch was plain wore out and was replaced with a nice Curt unit.
I kept only two pieces from it. This one, and the trailer plug cutout plate.










And with that all of the 'major' pieces are present.
« Last Edit: May 25, 2015, 10:46:47 PM by Sammconn »
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #36 on: May 25, 2015, 10:33:59 PM »
So on to the first round of finishing.



A little polishing with a flap disc to remove grinder bites!



I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #37 on: May 25, 2015, 10:35:52 PM »
And on with the acid etching primer.



I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #38 on: May 25, 2015, 10:38:16 PM »
The primer showed off all of the imperfections, and out came the bondo.





And sanded out.



I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #39 on: May 25, 2015, 10:42:40 PM »
With that, it was on to finishing.
I started with the bottom and inside of the bumper.
They got several good coats of rubberized undercoating.



After about a half hour of dry time I laid it down and shot the first of four coats of paint.





I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #40 on: May 25, 2015, 10:52:12 PM »
Added a whole lotta clear to it and let it sit for the night.



Come morning I had a buddy come over to give me a hand installing it.
I'd put the bumper sub 200# but I could be off. I could handle it fairly easily alone but didn't need to scuff the paint.





The ice is finally starting to go, this was early Sunday morning, by evening there was considerably more sinking and failing.


I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #41 on: May 25, 2015, 10:58:43 PM »
Onto the wiring of the winch. I seem to have missed the connections at the bumper but it is all ran up through the core support and in under the hood.
This is the circuit breaker bank that comes with the Badlands winch.



Covering up the exposed bus bars and terminals with two layers of heavy heat shrink.





And all tied in to the battery.


I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #42 on: May 25, 2015, 11:03:25 PM »
Well the winch works unloaded.
Snugged up onto a carribiner temporarily as I need to get a shackle.



The color worked out as a very close match.



I'm quite impressed for rattle can paint.



I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #43 on: May 25, 2015, 11:08:59 PM »
And that's about it folks.

I drove out to the city today, and with the amount of bugs that have become a fixture I'll be switching over to Raptor liner or some variant. The paint didn't take the few stones that it met very well either.

I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline JR

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Re: Sam's 2006 LBZ front bumper
« Reply #44 on: May 25, 2015, 11:13:09 PM »
That looks great. Color, workmanship and time!!!
Retired LEO  Lifetime NRA+  Outcast in Calif

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Re: Sam's 2006 LBZ front bumper
« Reply #45 on: May 25, 2015, 11:18:33 PM »
Very nice job Sam, very nice.

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Re: Sam's 2006 LBZ front bumper
« Reply #46 on: May 26, 2015, 01:33:27 AM »
Very nice, another example of building a heavy duty bumper. Don and Kyle just might have to have another subsection showing off the bumper builds on here.

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Re: Sam's 2006 LBZ front bumper
« Reply #47 on: May 26, 2015, 07:19:22 AM »
Great work.
Matt
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Offline Sammconn

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Re: Sam's 2006 LBZ front bumper
« Reply #48 on: May 26, 2015, 07:30:24 AM »
Thanks guys.
It's been a very tiring couple weeks.
I intend on doing the rear as well, but am taking a break.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

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Re: Sam's 2006 LBZ front bumper
« Reply #49 on: May 26, 2015, 07:31:17 AM »
That's nice work! Bringing back the art of building things in lieu of buying things. I like it for a variety of reasons. Unique, you own it from the start, strong, personalized, meets your needs, and you learned from building it.

Great job!

Oh, for a quality bumper like that consider these Warn premium clevis D rings
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