Thread: 110 Defender Bumperettes

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;



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!



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.







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:



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).







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.



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.





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





And attached to the vehicle....





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





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:





Side piece all welded on:







And an end piece to close up the box section:



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

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