Re: 60-66 Stepside rear step bumper modification
 

Had some problems keeping my gap by the bumper tip where it meets the fender. Every time I would apply heat to the channel the gap would change no matter how I clamped it down. I decided to just "cold tack it" until I have the diamond plate welded in to keep the angle and then go back and put some heat on the frame. After some time off to get a new plan I blasted and primed the frame and had some diamond plate bent. When I cut the plate to size, do I leave a gap for the weld, or leave it flush with the edge of the bumper channel?
Thanks murphy98

Re: 60-66 Stepside rear step bumper modification
 

Thanks 1963c-10, and thank you for the beauty ring suggestion, I really like them.
Thanks TJ, Been snooping around in the projects and builds to get ideas,:metal:

Re: 60-66 Stepside rear step bumper modification
 

Looking really good WhippinSaw! I can understand the trouble getting the gap right at the fender, hard to do a compound curve at the tip on thick material like that. I wonder if the original tips were done on some kind of stamping machine for consistency? I did leave the diamond plate set back from the edge of the bumper about 1/16" to allow room for the weld bead. Then I used a grinder to round over the edge & smooth out the welds to match the original continuous weld bead on the rest of the bumper.
You're doing a fantastic job, keep up the great work it will pay off when you're all done and ready for paint.
Murph

Re: 60-66 Stepside rear step bumper modification
 

Nice work it's looking good.

Re: 60-66 Stepside rear step bumper modification
 

Thanks for the encouragement Jeff, no experience at metal fab so I need all I can get.

I replaced my 55-59 drivers rear fender with a 60-66 fender, the 55-59 fenders are measurably and noticeably narrower than the 60-66. Shout out to TJ for shipping me a nice fender and informing me that I did have a 55-59 fender.

While I worked on replacing the fender I drove it around with a chopped barden bumper, I cut it short to remove some length from the straight part of the bumper and it looks better than it did already, it also weighs quite a bit less, like mentioned above, you could also cut the upper clevis plate out to reduce weight.

Re: 60-66 Stepside rear step bumper modification
 

I solved my problem of the extensions moving while applying heat to the C channel, I welded on a piece of angle iron on to hold it in place with no clamps required, I tried it at first with a piece of diamond plate, but had to switch to quarter inch angle to keep it in place, still only tacking it in place except for the top which will be unaccessible when I get the diamond plate welded in,

Re: 60-66 Stepside rear step bumper modification
 

Got the bumper tips bent up, I just put them in a vice and bent the ears down about 3/4 of an inch

Re: 60-66 Stepside rear step bumper modification
 

I wasn't sure how to attach the extensions to the fender so I came up with carriage bolts and rubber plugs, I only needed one bolt per side because it was strong enough with just one, but I thought I would need the extra strength and the fender TJ sold me had 2 holes in it. This also allowed me to dial in the gap with the bolt holding the extension in place while the diamond plate is being installed.

Re: 60-66 Stepside rear step bumper modification
 

All the diamond plate has been cut and just making final adjustments and checking lines before I weld it up this weekend.

Re: 60-66 Stepside rear step bumper modification
 

Nice work....can't wait to see it all done and painted!!!!

Re: 60-66 Stepside rear step bumper modification
 

Put some braces at an angle and some 3/16th plate on the butt joints to keep everything in place, after all that work I didn't want it to move and between the braces and the diamond plate I felt comfortable welding up the frame.

Re: 60-66 Stepside rear step bumper modification
 

painted it with argent silver as suggested by members on the forum, They were right, looks like it just came out of the dealer, I like it :metal:

Re: 60-66 Stepside rear step bumper modification
 

Wow! Amazing job WhippinSaw! You'd never know it was not like that originally, looks like you just got the dealer to install it! Really love the paint choice too!
Looks perfect:metal: Congratulations.

Murph

Re: 60-66 Stepside rear step bumper modification
 

Thanks for the compliment murphy98, I really like it, and thank you for your detailed mod and suggesting I could convert my fleetside bumper, I could never would of done it without your help, Thanks again murphy98

Re: 60-66 Stepside rear step bumper modification
 

Nice work on those bumpers, fellas! Really a good looking set-up.

Re: 60-66 Stepside rear step bumper modification
 

Yes a great job