110 Defender Bumperettes

[TimNZ]

Hi all, My latest project for my 110 has been a set of "Bumperettes". I was originally going to buy some, I was looking at the Bearmach Heavy Duty ones;

https://www.aulro.com/afvb/images/imported/2008/06/276.jpg

But although I liked the look of them, I didn't like the look of the price of them. Also they seem to be made for the 90 because the quarter panel protection looks very short for a 110. I wanted to make an extended version that went up to the mud flaps. And I'd managed to talk the boss into buying a Mig the week before.
All the steel I used was packaging from the machinery we import, so I had to make do with what I could scrounge since Perth shuts down on Sunday, and recycling is better for the enviroment.....
I'm going to make the bumperettes attach to the crossmember, but as you can see from the pic below the crossmember angles in underneath the body, just to make things a little bit harder!

https://www.aulro.com/afvb/images/imported/2008/06/277.jpg

I started off by holding up a bit of 50x50 box section with a couple of right angel welders magnets, (great bits of kit and cheep to!). I used some fairly thin walled, (2mm), box section for a couple of reasons. First I'd rather the bumperettes bent than my cross member, and second, that was all I had.

https://www.aulro.com/afvb/images/imported/2008/06/278.jpg

https://www.aulro.com/afvb/images/imported/2008/06/279.jpg

https://www.aulro.com/afvb/images/imported/2009/02/158.jpg

I postioned the box section 50mm away from the body, I also temporarily attached the pintle also to see how things line up. I want to make a full bumper eventually to strenghen the crossmember and incorporate a couple of recovery points, as you can see the crossmember is rather meek:

https://www.aulro.com/afvb/images/imported/2008/06/280.jpg

Righto, next I made a plate to bolt to the crossmember and cut a piece of 50x6mm plate to 49mm and welded the box section to the 6mm plate, and the 6mm plate to the plate that bolts on to the crossmember. (I did all the welding off the vehicle).

https://www.aulro.com/afvb/images/imported/2008/06/281.jpg

https://www.aulro.com/afvb/images/imported/2008/06/282.jpg

https://www.aulro.com/afvb/images/imported/2008/06/283.jpg

I've allowed the box section to protrude 15mm past the side of the body, so there's a decent gap between the side piece and the quarter panel. Now for the second plate that bolts to the crossmember.

https://www.aulro.com/afvb/images/imported/2008/06/284.jpg

I welded this plate to the box section with a 47mm length of 50x6mm plate. This piece is 2mm shorter than the piece on the left to allow for the angle of the crossmember end.

https://www.aulro.com/afvb/images/imported/2008/06/285.jpg

https://www.aulro.com/afvb/images/imported/2008/06/286.jpg

(Yes, I'm a amature welder!!!) Anyway, the so-far finished piece:

https://www.aulro.com/afvb/images/imported/2008/06/287.jpg

https://www.aulro.com/afvb/images/imported/2008/06/288.jpg

And attached to the vehicle....

https://www.aulro.com/afvb/images/imported/2008/06/289.jpg

https://www.aulro.com/afvb/images/imported/2008/06/290.jpg

Now for the side piece that protects the quarter panel. I cut this out of a piece of C section that was "available".

https://www.aulro.com/afvb/images/imported/2008/06/291.jpg

https://www.aulro.com/afvb/images/imported/2008/06/292.jpg

I then marked out the one for the other side of the vehicle, go the magnets! I've also found that "Whiteout" is great for writing on steel:

https://www.aulro.com/afvb/images/imported/2008/06/293.jpg

https://www.aulro.com/afvb/images/imported/2008/06/294.jpg

Side piece all welded on:

https://www.aulro.com/afvb/images/imported/2008/06/295.jpg

https://www.aulro.com/afvb/images/imported/2008/06/296.jpg

https://www.aulro.com/afvb/images/imported/2008/06/297.jpg

And an end piece to close up the box section:

https://www.aulro.com/afvb/images/imported/2008/06/298.jpg

Now I just need to make another one exactly the same for the other side! I'm going to get them powder coated matt black when they're finished, and depending on how they look I may put some chequer plate on the top of them, so I can use them as a step as well.

Thanks for reading!!

Tim

[Slunnie]

Looks pretty excellent!

I'd just add something to stop it moving sideways, such as from slapping around in ruts.

[weeds]

top job their

[long stroke]

Good work, lookin forward to the finished product!!

CHEERS TIM.

[numpty]

Nicely done. It always gives you satisfaction to make things up yourself.:BigThumb:

[tolinja]

man i iwsh i had the gear to do that, looks great i need the same thing but looks like i will have to buy mine :P

cheers
chaser

[D3Jon]

Nice work, thanks for taking the time to document it for the rest of us to see.

Nothing amateurish about those welds either! :) Top job.

Jon

[TimNZ]

Thanks for all the comments guys! If it's raining, (and I'm not too hungover!), I'll get the other one made tomorrow so I can get them off to the powder coater next week.
Thanks for the tip on the side braces Slunnie, I'll probably make up some stays that run up to the chassis.

Cheers,

Tim

[TimNZ]

Got the other one made today:

https://www.aulro.com/afvb/images/imported/2008/06/129.jpg

https://www.aulro.com/afvb/images/imported/2008/06/130.jpg

https://www.aulro.com/afvb/images/imported/2008/06/131.jpg

Off to the power coater tomorrow....

Cheers,

Tim

[weeds]

any chance you can make detailed measurements and sketch them and scan them over....there a couple of members that might just do up some electronic drawings

[long stroke]

They look great looking forward to seeing them powder coated and fitted!!

CHEERS TIM.

[TimNZ]

any chance you can make detailed measurements and sketch them and scan them over....there a couple of members that might just do up some electronic drawings


Hi Weeds, I'll draw them up in Aut0CAD or Inventor and post the drawings, just might take me a while! If anyone wants any dimensions in the mean time just ask.

Cheers,

Tim

[weeds]

Hi Weeds, I'll draw them up in Aut0CAD or Inventor and post the drawings, just might take me a while! If anyone wants any dimensions in the mean time just ask.

Cheers,

Tim

hey Tim.....would be good if you could knock them up electronically....i reckon i will make a set

this is the thread i tried to keep going http://www.aulro.com/afvb/general-chat/51445-anyone-cad-got-spare-time-4.html

i have the completed electronic drawings for sliders, if you would like them i can email them to you.

[County3.9]

Instead of CAD, do the drawings in Google sketch up. Free for anyone (just like Google earth) with internet. I've not used CAD but this is a great programe that we could all use to view the drawings on.

[9w2LYL]

very nice project, good finishing and look professional.. Very detail write up as well.. keep it up..

cheer

[slug_burner]

SolidWorks - Downloads (http://tinyurl.com/5cprp4)

take the above link and you will find some free downloads that will allow viewing of many CAD package files.

I used the eDrawings download to view a setup to hold two spares on the back of a deffy which someone posted on this site IIRC

[Bushman83]

Hey everyone..
After comming across this post during my research into bumperettes, I figured I'd give building my own a go too! Thanks to TimNZ for the inspiration to get out of bed on a weekend and do something constructive!
I made mine shorter so I could still access my jacking points. Due to my wheel carrier I used different mounting holes, and I also didn't have any c-channel or angle iron so used the same flat metal as the bolting plates. enjoy...

http://img83.imageshack.us/img83/8792/bumperette01as8.th.jpg (http://img83.imageshack.us/my.php?image=bumperette01as8.jpg])
http://img353.imageshack.us/img353/1046/bumperette02sf7.th.jpg (http://img353.imageshack.us/my.php?image=bumperette02sf7.jpg])
http://img353.imageshack.us/img353/389/bumperette03ic2.th.jpg (http://img353.imageshack.us/my.php?image=bumperette03ic2.jpg])
http://img353.imageshack.us/img353/4865/bumperette04yz1.th.jpg (http://img353.imageshack.us/my.php?image=bumperette04yz1.jpg])
http://img83.imageshack.us/img83/9874/bumperette05eo3.th.jpg (http://img83.imageshack.us/my.php?image=bumperette05eo3.jpg])

:)

[TimNZ]

Looks pretty good Bushman!! Reminds me that I need to draw up the ones I've made!

Tim