My DD Bronco, winch bumper and roll cage

fairlane_68 · #1 07-30-2010, 03:08 PM

These are pics of my completed tube winch bumper and roll cage for my daily driver Bronco. I used a JD2 Model 3 Bender, Cornwell tools notcher, a Lincoln One-Pak 225 (mig and tig), and an Esab MigMaster 275 to do these projects at home.

Transmission cooler

Previously mentioned trans cooler:

One of the spikes I got from Ballistic Fabrication, that I've gouged three pairs of shorts on:

Forgot about the rock sliders:

Cage mockup:

All in all, in my opinion, not bad for an amateur. Rear bumper's next, and I got a sweet idea in my head for it. It involves many spikes...

PRConnection · #2 08-03-2010, 09:30 AM

How were you able to weld the top side of the tubes on the role cage? Nice job on the bumper. How well do you think the oil cooler will las there is you are into trails with lots of branches ...... I would be concerned of puncture.

Dan

fairlane_68 · #3 08-03-2010, 10:22 AM

Quote:

Originally Posted by PRConnection

How were you able to weld the top side of the tubes on the role cage? Nice job on the bumper. How well do you think the oil cooler will las there is you are into trails with lots of branches ...... I would be concerned of puncture.

Dan

By not welding the cage to the floor until it was all welded in and cutting holes in the floor, I was able to put a 360* weld on all the tubes. That was one of the things have I learned since I put the cage in my Mustang. And the trans cooler is alot tougher than it looks. It used to be mounted in front of the AC condenser, and the way it was attached was pretty brutal. I was pulling small branches out of it then too, with the stock bumper in place.

CAPTAIN CNC · #4 08-04-2010, 09:09 AM

I like those points on the end of the tube. I've got a box of something similar turned up for exactly the same use. Also, some domed end caps and still need to machine up some couplings for removing part of a cage.

entropy · #5 08-04-2010, 11:06 AM

Quote:

Originally Posted by CAPTAIN CNC

I like those points on the end of the tube. I've got a box of something similar turned up for exactly the same use. Also, some domed end caps and still need to machine up some couplings for removing part of a cage.

I see these pointy things and cringe, shake my head, and laugh at the Death Race 2000 bling. Just me but they are just so "B" movie

It should be noted that most such safety (and function) hazards are illegal on any street driven vehicle by DOT.