My bumper build

[racrx7]

When no one makes any aftermarket bumpers for our van, there's always the option of building them. Here's a mock up of a rear bumper I will build for my van. It will also have a swing out spare tire holder incorporated. My pattern has two different ends. The right has multi facets while the left is pretty much strait forward. Hmmmm, which end do I go with? Feel free to comment, critique, laugh, make fun of. I'm open to all comments.

[H2OJoe]

Looking good. Please post pics when the final product is done.

[Astrophysics]

Very nice.
I like the tapered edges to increase ground clearance to edge of bumper.

If you really need just rear storage, you should look at Rola Dart folding hitch mount tray. About $450 at REI.

AP

I have one on my 2003 Astro AWD.

[VanGoGo]

I vote for the pattern you used on the drivers side.

[racrx7]

Looks like I'll go with the left side. Now to get some metal and cut the pieces out.

[Astrophysics]

If you fabricate the bumper from 3/16" thick steel or even 1/8" steel, it will be heavy.

How about using thick wall aluminum box tubing?
Or Aluminum I beam bumper to save weight?

There is a company called Aluminess in California that makes aluminum rear and front off road bumpers.

AP

[racrx7]

If you fabricate the bumper from 3/16" thick steel or even 1/8" steel, it will

I have yet to decide on what material to make the bumper out of. I'd prefer aluminum, but depends on the cost difference. I think the added weight of steel in the rear, if I go that route, shouldn't effect the van much. I have plenty of spring rate back there and ride height adjustment. The front is a different story. That bumper WILL be made of aluminum. I want to keep the weight on the front down to the absolute minimum. Even so far as to go with an all aluminum LS V8 when I make that swap.

[Herbie]

There is a company called Aluminess in California that makes aluminum rear and front off road bumpers.

Sadly, they're "too busy" to make one for Astros (yes, I tried).

[Stroverlander]

If you fabricate the bumper from 3/16" thick steel or even 1/8" steel, it will

I have yet to decide on what material to make the bumper out of. I'd prefer aluminum, but depends on the cost difference. I think the added weight of steel in the rear, if I go that route, shouldn't effect the van much. I have plenty of spring rate back there and ride height adjustment. The front is a different story. That bumper WILL be made of aluminum. I want to keep the weight on the front down to the absolute minimum. Even so far as to go with an all aluminum LS V8 when I make that swap.

Looking good!

I agree with the principle of not adding more weight to the front, especially since we have no way to really increase spring rate with our torsion bar setup. I'd really like to get the van on corner scales to see where it's at, just need to find someone locally.

[racrx7]

So I started the actual rear bumper build. All the pieces were cut with a plasma cutter using my foam board mock up pieces as a pattern. Below is the spare tire pocket. More to come.

[astrozam]

Always good to see a project happening

[racrx7]

Starting to take shape:-)

[racrx7]

[WoodButcher]

That's pretty!