Chevy & GMC Vans

As originally posted by BCSUVan on astrosafari.com: Posted: Aug. 24 2005,7:22

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I'm not ready to install an aftermarket front bumper. So here's what I did for some tow points. It's 1/4 steel and all cut with a metal cutting blade on my circular saw and bent with a sledge hammer. What a lot of work. (boy, sure wish I had a welder/torch and knew how to use it!!!!!!!!!!1

I seem to have to figure out how to do all my metal projects with a hammer, metal cutting blade, drill, and BOLTS!

This first pic is the tow point assembly all fabbed up and ready to install.



below is the notch I had to make in the steel part of the bumper.

More pics from BCSUVan:









So, this is for those who want to keep the stock bumper and have already lifted their bumper so as to have access to the lower bumper hole mount. I hope it holds strong enough since the bumper holes are actually only held in place by a steel cap welded on the end of the frame horn, not in the frame itself. However, that's why I ran one side of my assembly a little farther on the frame and bolted it there too.

Here is photo of steel plate bolted to cross member to mount tow hooks.

Astrophysics

I just unlocked my photobucket account, but the pictures still don't seem to be showing up. Any ideas?
Thanks

All fixed and some of the threads have been cleaned up as well...including these last in the next day or 2.

Awesome!
Astrophysics I think I like yours best...

Sorry it took me so long to accomodate your request here for pics, and thanks Dean for fixing the problem.

Your van looks good with the 2 tone paint. I like the side name plate too...Astro 4X4 ....emblem,
which replaces the AWD . Your D link swivels are cool. you could maybe build up a small rubber trim piece around them with some body or bumper molding.

I am still thinking of only a 2 inch lift....with stock AWD transfer case in my 2003...some day when it needs tranny rebuild i would like to get 2 speed transfer case and or lower axle gears, my stock is 3.42 good for freeway..

Astrophysics

Yes, a nice welder would be nice but we would all need to have clean shop space to avoid starting fires. I too use drills and sawzall and milwauke band saw. Simpson strong tie heavy angle etc
Still trying to fit Land Rover brush guard onto 2003 AWD
AP
This ipad 2 that my kids got me for Fathers day is nice but file structure must have a way to post photos? Or do i need to put photos on photo bucket?

Astrophysics wrote:Here is photo of steel plate bolted to cross member to mount tow hooks.

Astrophysics

I think I like this plan. I might go a little further and try to add a 2" receiver on top of the plate. I have a warn winch and want to mount it on a receiver hitch mount so it can pull from either end, another vehicle or simply be left at home when I don't need it.

I like the added strength to help keep from pinching the frame when using a bridle to pull. Also be a perfect front mounting point for a skid plate and maybe even a light weight brush guard..

That crossmember gets a lot of abuse on my van. IMO, the subframe points where the bumper is mounted is a better place.

Well, I changed my plans from beach campground to offroading into a desert campout at the last minute, and I still hadn't rigged any front recovery point, so I needed something and FAST. Here's what I came up with:

I'd always wanted a front receiver for the utility. I keep thinking about receiver-mounted winches, bike racks, or even a 2nd spare tire mount. I figured it ought to work ok for recovery too. AFAIK, nobody makes a dedicated front-receiver for the Astro/Safari, but I did recently find this "semi-universal" kit from Reese at Autozone (part# 37042) and after a little measuring, I was pretty sure I could make it work:

The starting point:


Made a cardboard template of the whole side plate, then kept trimming until it fit the inside of the subframe where the bumper mounts. NOTE: Measurement error, the hole spacing is 2-3/8", not 3.


Corrected measurement and after cutting down the side-plate on my band saw:


Starting to bolt things up. Did this for now, may re-visit this going forward. My bumper brackets are not-straight enough that I could probably put the receiver plate inside of it and still bolt everything up...


Getting things centered:


The upward flexing of the plastic looks much worse in the photo than IRL, but I'm still concerned about this a bit. Trying to figure out how to bend the tubing such that it projects forward a bit more - should provide more clearance:


A little trimming of the bumper:


And voila'


It doesn't sit any lower than the lip of the bumper, but does stick forward a bit, so I plan on leaving the shackle insert OUT until needed. Since it's now the limiting factor for my approach angle, I may look into adding one of those skidplate inserts (or tying in the skidplate if I ever get around to having one made). I only felt it catch once when I was bouncing nose-down into a very silty rut, but everything still looked good.

Again, this was all done in a bit of a hurry (2 days before the trip), so I may revisit some of the mounting, but I'd love to get first impressions from everyone.

Love it, but I would probably weld those side mounts. With a winch, or even a good tug from a fellow off-roader, I think the mounts might twist up or down if the force isn't straight forward. (You had to cut off the length that would have given that stability.)

looks clean and i like the idea of a more center pull it offers, instead of the radically wide left side or right side pull.

I haven't figured one out yet, so I keep wrapping a Keeper strap arouond the front frame, then coil it up and zip tie it behind the front plastic facia up underneath, with just the end loop outside the facia, zip tied in a spot that i can grab it if stuck and cut the zip tie.

*Remember, loops only; no hooks on the strap.

I actually ride with a guy who tests metal failure for Peterbuilt and Kenworth, including recovery points. he is a very helpful dude and volunteered to help me design and test mine when i'm ready. Maybe yet this spring.


If you zoom in yu can barely see the snow packed loop of the strap zip tied to the bottom screw hole of the license plate.

The only thing I would change is welding the side plates to the frame and placing the bumper relocation brackets on the outside. You also need longer bolts unless they are only started in the pics. By welding the backside of the vertical section to the frame I would not be worried about banging it on rocks or using it for winching.

I might just use this thread as a starting point for mounting the same receiver hitch on the front of my truck to haul bikes while camping!