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I like the shape of that bumper. Looks really sweet. Be sure to cut holes in the top of the bumper so you can access the controls on the winch.

And I will ditto what Onpoint said about the fender rubbing and flex. All 3 of those points where he showed the bumper would rub is exactly where mine rubbed. Rubbed right through the paint on the fender and right through the bed liner on my bumper. Made awful sounds anytime the truck moved. I was able to bend those parts of the fender away from the bumper and I replaced the center bar with a new one I made from angled aluminum. You need 1/2" minimum between the bumper and the fender. Note the spacing between the bumper and the fender when I had the truck suspension flexing. It's even all the way across when not flexed.
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Discussion starter · #24 ·
Posted more pictures on the front page of what i got done today only had a few hours to work on it.
 
Flux core?
 
Discussion starter · #27 ·
You talking about flux core mig welding wire?
Yeah, are you using it? I noticed a lot of slag dust around the tacks, unless I'm just nuts.

I gave up and got a bottle of C-25 halfway through my headache rack build because it got hard to clean out of tight corners.
 
Discussion starter · #29 ·
Yeah i should probably do the same, but I have been using it this way for years. How do you like it on gas, is it really a lot cleaner? I tack weld the whole unit then take it off and double tack weld the back to lock everything in place then seam weld all the joints from the front. I also seam weld all the 1/4 plate and reinforcements that I install. But I do have alot of grinding on the face to get the results I am looking for. Sometimes it sucks being a perfectionist.
 
I vote for 2 sets of fogs on it. That's BA!
 
Gas will give you alot better looking weld. I almost always use flux cored with our Miller Renegade 180. My friend has gas for his Miller and it sure does make it nice.
 
Discussion starter · #34 ·
Added some pictures of the progress I made. The fabrication is all done, just seam welding and grinding(takes quite some time) hopefully be done with all that tomorrow and be able to spray it and get it installed maybe Monday.
 
Looks good. You gonna paint it or linex it?
 
Dude... you are killing me. I want that monster... shoot I would be happy with a light bar like the one you got on there.
 
Discussion starter · #39 ·
I could probably fabricate a similar light bar that would work with the factory bumper!! Is anyone interested in that, I can fabricate one up and figure out what the cost would be for you guys.

Also just covered one set of fogs with yellow film check it out

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Oh yeah I am gonna spray it with line-x material.
 
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Discussion starter · #40 ·
Can't wait to slap this bad boy on and start my next fabrication......???? Hahahah can anyone guess what that will be?
 
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