Making your own HD bumper... thoughts?

Clarky130 · Jul 21, 2012

I had an idea... I know where I can get hold of some scaffolding poles, and thought I might have a go at fabricating my own HD bumpers...

Question is, are they up to the job? I belive they're 2" OD (standard scaffolding size?) and the plan would be to weld 2 together, one on top of the other, and either cut 'n weld or bend (if possible) to mimick the slight angling back of the commercially available ones - and, obviously, welding on sufficiently sturdy mounting brackets.

Would standard scaffold poles not be large / thick enough to take the required punishment? Or would they work quite well? Has anyone else tried something similar?

And for those who have tubular HD bumpers... what diameter is the tubing?

They're for a Disco 1, btw...

300tdistu · Jul 21, 2012

sirwingalot · Jul 21, 2012

sirwingalot · Jul 21, 2012

sirwingalot · Jul 21, 2012

maybe

300tdistu · Jul 21, 2012

Are they galvanised ?
if they are you will get poisonous fumes !!! they will splutter and spit.

Spunka · Jul 21, 2012

When makeing a home made bumper the trick is the strength should be in the design . A lot of folk use to heavy gadge steel and over enginer them.end up with something for a tank.

mad git · Jul 21, 2012

300tdistu said:
Are they galvanised ?
if they are you will get poisonous fumes !!! they will splutter and spit.

Not poisonous exactly, just grind it off first.....

The Mad Hat Man · Jul 21, 2012

300tdistu said:
Are they galvanised ?
if they are you will get poisonous fumes !!! they will splutter and spit.

Bolixx
absolute tosh
Zinc (Galvo) fumes are not toxic at all.
Read the thread in the FAQ section

.

They do give of fumes tho (best to weld in open air) and can give flu like symptoms for up to 24 hours if you breath the fumes alot.
Just clean off Galv where yu intend to weld and use a weld thru primer to protect it short term, if you have to.

Hamsterberg · Jul 21, 2012

If you have to weld galvo drink a pint of milk as it does prevent the flu symtoms

Spunka · Jul 21, 2012

Whether poison or not its like none Asbestos brake lineings , You dont want to breath that **** in
:hippie:

300tdistu · Jul 21, 2012

mad git said:
Not poisonous exactly, just grind it off first.....

you cant grind it from the inside

The Mad Hat Man said:
Bolixx
absolute tosh
Zinc (Galvo) fumes are not toxic at all.
Read the thread in the FAQ section .

They do give of fumes tho (best to weld in open air) and can give flu like symptoms for up to 24 hours if you breath the fumes alot.
Just clean off Galv where yu intend to weld and use a weld thru primer to protect it short term, if you have to.

ok it not going to kill you........ but you will feel ill

why not just pop down to your local steel place and buy the right stuff for the job, scaff tube is not right for a bumper

chunkymunky · Jul 21, 2012

Make it from steel tubing fit it,check it,be happy then get it galvanized. Not that costly. Place near worcester will gakvanize a bulkhead for £50

Clarky130 · Jul 21, 2012

So... wear a mask under me welding helmet then?

Gonna have this issue anyhow, as I've bought boot floor sides from YRM... which are Zintek panels... big fan in the back doorway to aid ventilation, methinks...

Clarky130 · Jul 21, 2012

300tdistu said:
you cant grind it from the inside

ok it not going to kill you........ but you will feel ill

why not just pop down to your local steel place and buy the right stuff for the job, scaff tube is not right for a bumper

'Cos the scaff tube may be coming my way for 'free'

chunkymunky · Jul 21, 2012

Dunno then. Research first i guess on safe way.of doing it. Ventilated, canistered mask when you weld?

Hamsterberg · Jul 21, 2012

Grind off galvo where your going to weld, its going to come off anyway when you weld it and if you weld with it on it will spit and not be as good.

200tdi ayre · Jul 21, 2012

my first thought is that it wont be strong enough to take direct impacts, but there's only one way to find out

plus its a good learning excercise i've gone through 3 light bars so far, slowly making them better

Sean · Jul 21, 2012

make a roll cage while you're at it

ricc · Jul 21, 2012

ive welded lots of galv tube over the years, grind off where yer welding as you would with paint or rust, if youre working outside you shoudnt have any problem with the fumes ... i never have. and have never worn any form of mask for the fumes.

Making your own HD bumper... thoughts?

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