Author Topic: SquareD Part 6 Bumpers, Winches, wiring, lights, assembly (Read 453928 times)

Flyin6 · « **Reply #500 on:** May 14, 2015, 10:11:10 PM »

Next up I cut out the back and outer, top pieces which were rather complex cuts with many angles

Flyin6 · « **Reply #501 on:** May 14, 2015, 10:14:44 PM »

The back caps were first then the top section which I bent some to have an upward tilt to it

Flyin6 · « **Reply #502 on:** May 14, 2015, 10:15:53 PM »

The left side fit was not all that great, so I tacked it in place anyway. I'll grind it flush when I pull the bumper off for final welding after fitting up is done

Flyin6 · « **Reply #503 on:** May 14, 2015, 10:18:12 PM »

The right side went better but I ran out of wire right in the middle of tacking that top piece, so it is not completely tacked in yet

Flyin6 · « **Reply #504 on:** May 14, 2015, 10:19:47 PM »

The plasma still worked so I cut out the top pieces for the winch surround

Flyin6 · « **Reply #505 on:** May 14, 2015, 10:21:14 PM »

That area is going to get a bunch more work with the addition of some old school and ARB bumper style uprights and some steel tubing

Flyin6 · « **Reply #506 on:** May 14, 2015, 10:22:59 PM »

I shot some better pics of the interior since those other ones caused Mike to get vertigo

Flyin6 · « **Reply #507 on:** May 14, 2015, 10:25:07 PM »

So that was the end of a half completed work day...was off to buy welding wire, get groceries, then shower, feed the dogs, see what's wrong with the black and white cat...ah, the patches cat is in heat again.

Pulley · « **Reply #508 on:** May 14, 2015, 10:27:25 PM »

Really liking the bumper, turning out great. Keep up the great work.

JR · « **Reply #509 on:** May 15, 2015, 02:20:03 AM »

I want to see how you do the protection up front so that purdy sheet metal and grill stay purdy.

Flyin6 · « **Reply #510 on:** May 15, 2015, 08:29:37 AM »

Quote from: JR on May 15, 2015, 02:20:03 AM

I want to see how you do the protection up front so that purdy sheet metal and grill stay purdy.

With a tail-wind and any luck at all, you should begin to see that happening today

JR · « **Reply #511 on:** May 15, 2015, 02:15:09 PM »

Quote from: Flyin6 on May 15, 2015, 08:29:37 AM

Quote from: JR on May 15, 2015, 02:20:03 AM
I want to see how you do the protection up front so that purdy sheet metal and grill stay purdy.
With a tail-wind and any luck at all, you should begin to see that happening today

Well at least we know you have a new roll of wire,,,,,,,,,,,,

Good Luck!!

cudakidd53 · « **Reply #512 on:** May 15, 2015, 05:35:47 PM »

"Vertigo..." Wasn't the photos, it was the idea of you, wood and fiberglass again!

"Pre-rangers- procure new saw blades and wait in the wings with Red Dog for Operation Hide Mistake 2" :o

Flyin6 · « **Reply #513 on:** May 15, 2015, 06:56:07 PM »

Quote from: cudakidd53 on May 15, 2015, 05:35:47 PM

"Vertigo..." Wasn't the photos, it was the idea of you, wood and fiberglass again!

"Pre-rangers- procure new saw blades and wait in the wings with Red Dog for Operation Hide Mistake 2" :o

Speaking of vertigo, Mike, how are you doing? See the Doc? Find out anything?

Flyin6 · « **Reply #514 on:** May 15, 2015, 06:58:21 PM »

OK got the uprights built and on. Man that was a bunch of time and work, some 6 hours in all

First I addressed the front winch, welding those pieces onto the top of the fairhead plate

Flyin6 · « **Reply #515 on:** May 15, 2015, 07:00:07 PM »

I cut the right side piece twice and it was still too short, so I owe it a patch there. I added the tiny pizza slice parts to close all that in

Flyin6 · « **Reply #516 on:** May 15, 2015, 07:01:19 PM »

Next the uprights were sketched out

Flyin6 · « **Reply #517 on:** May 15, 2015, 07:02:40 PM »

Those suckers are pretty tall. Two of them will gobble up a large .250" plate I'm guessing.

They will eventually fit like this:

Flyin6 · « **Reply #518 on:** May 15, 2015, 07:03:44 PM »

Like I said they gobbled up the largest piece of .250" plate I had

Flyin6 · « **Reply #519 on:** May 15, 2015, 07:05:13 PM »

Finish grinding and drilling all those 1.75" holes took time and patience and a goodly amount of cutting oil

Flyin6 · « **Reply #520 on:** May 15, 2015, 07:06:11 PM »

But in the end the grinder won out

Flyin6 · « **Reply #521 on:** May 15, 2015, 07:08:25 PM »

I removed a lot of unnecessary material to lighten the structure, but I am going to gain back a ton of strength my making these uprights into I-Beams by adding this section of 3/16" X 3/4" to the outside edge

Flyin6 · « **Reply #522 on:** May 15, 2015, 07:09:49 PM »

Here they are with the piece added

Flyin6 · « **Reply #523 on:** May 15, 2015, 07:12:02 PM »

This is how it will fit with the 1.75" DOM I have to make a brush guard from

Flyin6 · « **Reply #524 on:** May 15, 2015, 07:13:17 PM »

First one aligned and on

Flyin6 · « **Reply #525 on:** May 15, 2015, 07:14:31 PM »

Then the second one

Flyin6 · « **Reply #526 on:** May 15, 2015, 07:16:41 PM »

And with a couple sticks of the DOM shoved in there to check alignment and get a concept of where to run the next bars to build the brush and deer killin' feature to this truck's front end

duramaxdarren · « **Reply #527 on:** May 15, 2015, 08:03:01 PM »

don, the bumper is absolutely awesome. i have a small concern though, the clearance to the fender is a lil tight for my liking. just a thought on body flex and roll. i know it should all move as unit but still i wouldn't want that to become an issue

Flyin6 · « **Reply #528 on:** May 15, 2015, 08:32:58 PM »

Quote from: duramaxdarren on May 15, 2015, 08:03:01 PM

don, the bumper is absolutely awesome. i have a small concern though, the clearance to the fender is a lil tight for my liking. just a thought on body flex and roll. i know it should all move as unit but still i wouldn't want that to become an issue

I'm watching that

Either it will work or it won't!

duramaxdarren · « **Reply #529 on:** May 15, 2015, 08:48:13 PM »

well put ;)

cudakidd53 · « **Reply #530 on:** May 15, 2015, 11:20:17 PM »

Quote from: Flyin6 on May 15, 2015, 06:56:07 PM

Quote from: cudakidd53 on May 15, 2015, 05:35:47 PM
"Vertigo..." Wasn't the photos, it was the idea of you, wood and fiberglass again!

"Pre-rangers- procure new saw blades and wait in the wings with Red Dog for Operation Hide Mistake 2" :o
Speaking of vertigo, Mike, how are you doing? See the Doc? Find out anything?

Well, Quack in the Box set me up with drops for an outer ear infection, Drammamine, Clairetin and seem to be improving- but I'm gonna get to the real Dr/Cardiologist to get back on cholesterol meds as my level (NATO round) and heredity dictate I should be doing so AND to make certain it was just ear infection. Appreciate the prayers and inquiry. MORE SPARKS!!!!!!

akraven · « **Reply #531 on:** May 16, 2015, 03:18:26 AM »

That is an awesome job you are doing on that bumper Don! Are you going to include shackle mounts or D-rings on it?

Flyin6 · « **Reply #532 on:** May 16, 2015, 07:32:03 AM »

Quote from: akraven on May 16, 2015, 03:18:26 AM

That is an awesome job you are doing on that bumper Don! Are you going to include shackle mounts or D-rings on it?

I'll be adding these:

Flyin6 · « **Reply #533 on:** May 16, 2015, 08:12:40 AM »

Thinking about adding these as well. 47,000 lbs breaking strength, 15,600 working strength so they work within the winch limits. A pair front and rear along with the clevis mounts would give me a full strength choice in case someone stole the clevis or I am using chains

KensAuto · « **Reply #534 on:** May 16, 2015, 09:32:49 AM »

Quote from: Flyin6 on May 15, 2015, 08:32:58 PM

I'm watching that

Either it will work or it won't!

A good point......but......
Remember what happened to mine after welding it up solid ? yeah, it sucked it together no matter how I did it....I was stitch welding no more than 1" at a time, alternating sides. had to use a porta power to stretch it back enough just to get it back on the truck!!
Looking good buddy, continue. I'm doin' a pretty cool project today myself, in between getting a new (old) 5th wheel.

Flyin6 · « **Reply #535 on:** May 16, 2015, 10:21:07 AM »

Quote from: KensAuto on May 16, 2015, 09:32:49 AM

Quote from: Flyin6 on May 15, 2015, 08:32:58 PM
I'm watching that

Either it will work or it won't!
A good point......but......
Remember what happened to mine after welding it up solid ? yeah, it sucked it together no matter how I did it....I was stitch welding no more than 1" at a time, alternating sides. had to use a porta power to stretch it back enough just to get it back on the truck!!
Looking good buddy, continue. I'm doin' a pretty cool project today myself, in between getting a new (old) 5th wheel.

Sweet!

Post it up!

Flyin6 · « **Reply #536 on:** May 16, 2015, 11:44:37 AM »

Just ordered 4 of those weld on 1" D-rings

I'll stick them on somewhere on the front and the rear

Flyin6 · « **Reply #537 on:** May 16, 2015, 01:09:08 PM »

Picked these up off of Amazon.

Wanted to try some "flush" mount LED's in lieu of carving out a hole to mount some dirt collecting light fixture inside

Good price as well $75 for all 4!

JR · « **Reply #538 on:** May 16, 2015, 02:01:44 PM »

I love the lights and the hooks, can't have enough of either. I have some D ring tabs that go through the bumper for more grab.

I have several of those 6x led work lights and they are nice. Used em with small lithium packs.

I had concerns about how tight the clearance is too. It is gonna move, you are gonna help it sometimes with twisting and pushing. Clearance is your friend.

JR · « **Reply #539 on:** May 16, 2015, 02:13:15 PM »

Out of curiosity, does EMP affect led lights? since they work off 12v and are stepped down to 3-5v I guess it may depend on the circut? A resistor voltage drop system should be fine but based on a transistor your SOOL?

Nate · « **Reply #540 on:** May 16, 2015, 04:45:38 PM »

JR, I know this is not exactly what it is that you are looking for, but I think there is a great deal of information that we can all learn from.

http://www.futurescience.com/emp/vehicles.html

http://www.futurescience.com/emp/EMP-myths.html

https://www.google.com/?gws_rd=ssl#q=just+what+exactly+will+an+emp+effect

BobbyB · « **Reply #541 on:** May 16, 2015, 05:05:30 PM »

Quote from: Flyin6 on May 16, 2015, 01:09:08 PM

Picked these up off of Amazon.

Wanted to try some "flush" mount LED's in lieu of carving out a hole to mount some dirt collecting light fixture inside

Good price as well $75 for all 4!

If they look like the ones I've looked at, you'll still have to place a cutout and slide them into place, but one they are mounted they are flush or close to it.

Flyin6 · « **Reply #542 on:** May 16, 2015, 08:05:46 PM »

Quote from: BobbyB on May 16, 2015, 05:05:30 PM

Quote from: Flyin6 on May 16, 2015, 01:09:08 PM
Picked these up off of Amazon.

Wanted to try some "flush" mount LED's in lieu of carving out a hole to mount some dirt collecting light fixture inside

Good price as well $75 for all 4!

If they look like the ones I've looked at, you'll still have to place a cutout and slide them into place, but one they are mounted they are flush or close to it.

Copy that. I plan on doing that sort of stuff once I have it mocked up and on the plywood welding table. You do have to cut an access. Blue light saber tool will make quick holes in anything!

Flyin6 · « **Reply #543 on:** May 16, 2015, 08:09:06 PM »

Quote from: JR on May 16, 2015, 02:13:15 PM

Out of curiosity, does EMP affect led lights? since they work off 12v and are stepped down to 3-5v I guess it may depend on the circut? A resistor voltage drop system should be fine but based on a transistor your SOOL?

Depends on the type of circuit and the power of the pulse. Micro circuits give it up easy, but big things like resistors and windings and maybe bigger diodes should fare pretty well. But if there is a big pulse, even wiring might catch fire. Back in the late 19th century a massive solar flare and SME caused telegraph wires to throw sparks and start fires. The pulse wiped out the lines for some time. That's wire! Not a circuit. An artificially created pulse from a large nuke will easily make that much power. We be toast if that happens.

Sammconn · « **Reply #544 on:** May 16, 2015, 11:32:55 PM »

Those are the same lights I am thinking of putting in mine too.
Did get started on the front bumper today finally. And as my luck would have it, it's snowing again... >:(
So once I make some progress I'll post my bumper build up.
Hard to start a build thread 9 years in, but I'll get one going even if it is just a story at the start.

KensAuto · « **Reply #545 on:** May 17, 2015, 01:19:48 AM »

Quote from: Flyin6 on May 16, 2015, 01:09:08 PM

Picked these up off of Amazon.

Wanted to try some "flush" mount LED's in lieu of carving out a hole to mount some dirt collecting light fixture inside

Good price as well $75 for all 4!

Hmm, seen those somewhere before. :)

Flyin6 · « **Reply #546 on:** May 18, 2015, 08:36:27 PM »

Got a little bit more done on the truck today.

Balancing act now...Have the privy build going on, farm stuff, domestic stuff, meetings and geesh....

The welder finally could weld no more! The liner just wore out and was shuttling wire and not feeding it. So off to the Miller store I went. I bought a new liner and all new pieces parts to make it like new. Then I spent some time going over it, taping this tightening that. In the end I had a nice running machine and time to get back into the game!

Flyin6 · « **Reply #547 on:** May 18, 2015, 08:37:59 PM »

Speaking of domestic stuff, this morning I am getting the boneheads fired up and ready for school. This one comes in with this stuck around his neck! I should have left it there!

Flyin6 · « **Reply #548 on:** May 18, 2015, 08:40:39 PM »

I figured out that I will need one more horizontal bar on that front brush guard to keep trees out of operational spaces

So I fashioned up this extension arm that will serve as the base for the third row of tubing

Flyin6 · « **Reply #549 on:** May 18, 2015, 08:41:20 PM »

Found a piece of 1/4" plate and made the cuts