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Area51 Project Foreman - Custom Rear Bumper Build:
Having built my first custom bumper nearly 10 years ago, I decided that now was
the time to finally build a matching bumper for the rear of project Foreman.
Part of the reason was that my shed in Mount Pearl wasn't set up for welding,
but now I'm fully operational here in Torbay.
The old bumper was a dual tube that matched the old Front Bumper an also came with the bike when I purchased it new in 1998. Many smacks and weakening of the tubes rusting inside out meant it was time for an upgrade.
I began by making a cardboard
template just like I did last time.
This bumper was fabricated from a piece of 5' 3/16th thick C-channel steel. I transferred the markings from my template to the material.
The angles were cut to imitate the front bumper, and the bends were done exactly as before with a wedge removed from the top edge and a vertical relief cut 3/4 way through the steel on the back side.
Using a jig, I laid the bumper in place so that it didn't block the taillights or the truck cover for the storage compartment. I mocked up the mounting system to give even better access to the trunk than the old bumper.
The mounts were made from 1" square stock, the angles figured from the jig. The top mounts will bolt down through two flat areas on the rack, the bottom will pinch the round tubing just like the old bumper.
I'm very pleased with the outcome of this project. The end result is very unique, strong and will last a very long time. Cheers, MIKE
Project Pages:
Copyright © 2011 Michael Smith
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