M1009 Custom Front Bumper Build

jacksmad1

Member
63
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Location
Franklin, KY
I was wanting to buy a heavier duty bumper for my M1009 but could not find what I wanted exactly and also could not afford to buy one that was close. I decided that to get one like I wanted I was going to have to build it myself. The problem was although I had a wire welder I had never fabricated anything this big from scratch. I had only used the welder to repair implements for my tractor and various other small projects. Also since I did not have any drawings or measurements to build from I decided to use CAD or Cardboard Aided Design. Cardboard is a lot cheaper than steel and once designed the cardboard is used as templates to cut the steel.

The following thread will document my process.

As it started, there was nothing wrong with the original bumper and guard but I wanted something more heavy duty. I removed and saved all the original bumper and hardware so if my grandson wants to return to original he can when he inherits the vehicle.

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Bumper removed and beginning CAD design.

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Originally the bumper stuck out too far after looking at it and I had to cut it back.

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jacksmad1

Member
63
28
18
Location
Franklin, KY
I wanted to allow for future installation of a winch and fairlead so I went to local Tractor Supply to take measurements and photos

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First cuts of steel with newly acquired plasma cutter from Ebay.

Probably heavier than needed but I used 1/4" steel.

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jacksmad1

Member
63
28
18
Location
Franklin, KY
Mounted front plates and internal mount for winch. Measurements for fairlead on front of bumper. Also I had mounted a 2" receiver hitch into the front bumper which I will show more detail in later photos.


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jacksmad1

Member
63
28
18
Location
Franklin, KY
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Although when I cut the parts for one side and made mods to fit I would cut the other side at the same time but they would normally need some massaging as the fenders etc. would normally not be symmetrical.
 
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jacksmad1

Member
63
28
18
Location
Franklin, KY
In previous photos I had also made the covers for the winch and fairlead holes. I welded some small tabs inside the winch hole to bolt to which can be removed when winch is installed.

After studying on this setup for awhile I decided the uprights for the brush bar did not look meaty enough so I welded in another one on each side and then wrapped them with 1" x 3/16" inch strap.

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Bought a used Harbor Freight pipe bender and bent the side brush guards.

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jacksmad1

Member
63
28
18
Location
Franklin, KY
I bought the two pieces for the chain rings online from eBay so they would we beefy enough to hold up.

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So far most things were just tacked together, now I removed the bumper to burn it all in.

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Here you can see under the winch mounting plate and the 2" receiver.

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The receiver is not fully welded yet but was later.

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jacksmad1

Member
63
28
18
Location
Franklin, KY
I welded attachments to the bumper to bolt to the diagonal braces to the frame which are also bolted on.

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Box around winch totally welded on both sides to uprights at winch plate and bumper top for lateral strength.


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You can see the diagonal braces from the frame mounted on the M1009.
 
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jacksmad1

Member
63
28
18
Location
Franklin, KY
Added additional uprights for the brush guard. IMG_5043.JPG

Also notice I had cut holes for blackout running lights and additional led driving lights.

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Made sure to properly weld all connections.

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First coat of paint.
 

ssdvc

Well-known member
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Location
CT
That is one beefy bumper. I am not an engineer (didn't even sleep at a Holiday Inn last night), but are you planing to add any gussets to the two main vertical bumper attachment plates and the side extensions? Is 1/4" going to be enough to take a load (sideways or even directly in front) if you were to use a winch?
 

jacksmad1

Member
63
28
18
Location
Franklin, KY
That is one beefy bumper. I am not an engineer (didn't even sleep at a Holiday Inn last night), but are you planing to add any gussets to the two main vertical bumper attachment plates and the side extensions? Is 1/4" going to be enough to take a load (sideways or even directly in front) if you were to use a winch?
Notice in the previous photos the 2" rectangular tubing that is 1/4" thick that is mounted to the truck frame and extend to the front corners of the bumper. Also the top of the bumper and the winch plate are both fully welded to the uprights that are bolted to the frame which forms a box. Am I missing something else?
 

Mullaney

Well-known member
Supporting Vendor
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