Username: 2008 LE
Year: 2008
Make: Nissan
Model: Frontier
Trim: LE
Color: Grey
Mods: Radiator "SMOD" tran cooler bypass (replaced with new radiator)
Interior: Wireless Back up camera, Go Pro Hero camera.
Exterior: Homemade front bumper w/ 8500 lb superwinch mounted in it, rear hitch receiver and wiring, Wireless winch control, Tonno-pro lo-roll cover, bracket mounted LED lights (2x27 watt floods), Beacon light for plowing, customized bed mounted bike racks, Malone kayak racks (J-hooks), bug shield.
Drivetrain: Lokka Front Diff Autolocker
Suspension & Tires: 2.5" front lifted with Bilstein 5100's, 2" blocks in rear
Rims: Stock 17" LE
Summer tires: Michelin Latitude m/s 265/65R17's
Winter tires: BFG KO2 33's on 16" procomp 1089 polished rims
Armor: black widow offroad engine/rad skid plate
Performance: AFe Power Cat back, muffled replaced with Magnaflow 12580 (AFe was too loud for my taste)
Gear and Other: Snowbear 82" snowplow, 4000 lb utility winch, chains on front and back.
Started my bumper build finally. Started out with this design in CAD, then picked up some metal and started cutting. The longest part for me was figured out where to put the winch that I could keep as much approach angle as possible. Had to notch out the upper valance a bit to make a hole to use the clutch lever and also had to move the solenoid box as it was way too high. Now that I have it figured it and the sides of the winch cradle made the rest should go fairly smoothly. I picked up a dry cut metal saw, it really made chopping the 30 deg angle a breeze. Also converted my badsaw to metal cutting for now, have been impressed by how straight the cuts have been on that too.
Got the cradle all welded up and the large angled runs for the bumper "wings" chopped up on the bandsaw. Still a newbie welder but starting to get the hang of it a little bit.
It looks like a bumper finally! Left I have to cut and tack on the side peices, fill in some welds and add a few gussets on the wing to cradle section.
finished up all the sides and I am pretty happy with how it turned out. Ran out of welding wire though have to pick more up and finish up along some of the seams, then get the tube part made up. Still have nt decided if I will try to find someone to bend it for me or if I will just cut it and weld the angles I want.
Fully welded and ground down all the seams, and cut out the clevis mount wideners. Hoping it did nt contract any while welding, I tried to keep it even and not stick to a seam too long, but I am new at this hah. Decided to make the skid plate bolt on it will make removing the winch easier, and also will make it so that the bumper is a breeze to take off. Will post some pics tomorrow.
Yeah the bandsaw I have has about a 4 in drive wheel directly off the motor shaft. Take the wheel off and run a bigger belt on the shaft and it slows it down to metal cutting speeds (I can't remember exact specs but something like 500 fpm to 220 ish). It's been great so far.
Finished up welding, picked up a chunk o steel for the front skidplate and then welded on some runners to mount it to. I tapped out holes since I hate weldnuts so much. Just a bit more painting this evening, then its finished except for rewiring the winch solenoid.
Finished it up and mounted it back on, spent a bunch of time making an extension for the winch controller socket.....then I mount it all up and see that the socket is accessable left in the box hah. I will post some daytime pics tomorrow.
Daytime pic. The messiest weld on the whole bumper of course ended up being the one on the flat part of the front but oh well lots of room for improvement in my welding skills.
Started on changing the angle on the front of my skid plate, its going to be a bit of a mission wrestling it on the badsaw, otherwise should be fairly straightforward...
was actually pretty easy to cut, now just have to drill and tap some holes bolt this up in place and weld one side. may add some wings up around the sides of the rad does nt seem too protected there.
That was a lot more work than I thought it would be but it turned out ok, still have some small gaps I will fill in at some point but I am pretty happy with the approach angle, I don t think I could get much more with a winch installed.
Started measurements for some sliders, I will steal another members idea to use just a square piece for a rail then a round tube outer rail with them connected at an angle so then there is no need for bending, its tough to not use this as an excuse to buy a bender and notching kit though I will admit.
Got some bilstein 5125's tried to install but the bolts were super seized I had a 24" breaker bar on it and it was flexing 5 inches or so...called a local shop for a quote and they said 50 buck so I was sold. Have them installing Tuesday.
Great DIY work thus far - I like where you are heading with your mods and with your welding. Have you thought about adding a light on top of your bumper to cover that notch you cut in the valance?
Thanks its been a fun project so far. Hmm thats a good idea. I was going to add a door out of the material I cut out and a hoop at some point that might cover it. I have the harnesses sitting there from the fog lights that I may or may not ever get around to putting in the bumper.
Had the shop up the road install bilstein 5125's 2-4" variant. Bought them used from a member here and installed them the same way they were already setup boot up. Doesn't seem to matter much on these from what I could find but can switch them later if corrosion gets too bad.
Chopped up some 3/16" rubber to make a valance over the winch clutch lever.....not sure if I like it or not I think I will put it on though as it will help reduce how much slush gets in there in the winter if nothing else.
Before and after just waiting to put another couple of oats of tremclad on then will bolt it up. Welds were messy today mask kept fogging up...but I ground the front side down so its not too bad.