I spent a bunch of hours on the new bumper on Saturday. This is taking much longer than I anticipated, but it sure is fun.
I tapped the small hole i the frame so I could bolt in a backing plate for the bumper mount. Once the pumper is done there would be no way to get to the nuts inside the frame rail so I welded the nuts to a plate that is bolted in place. This plate needs to be removable to get to the bed mount bolts beside the gas tank.
I started with getting the top plate on and the back plate trued up to it. The bar stock was warped a bit and warped even more when I burned it to the 1" bar stock for the mount. I figured out the profile on the corner using some CAD (cardboard Aided Design).
Then came the upper bevel with some 2" bar stock.
The back face is 4" bar stock and I built the center step out of 4" as well. The support for the step was 2" bar stock ripped down to 1"... that was fun with a cut off wheel.
There is still a bunch of work to be done, but I am making good progress, The drivers' side upper portion needs finished up and then I can add the lower bevel pieces and bottom plate.