Road Rhino Weld it Yourself Bumpers

[Endica]

I haven’t seen much on here about these kits or bumpers so I wanted to show you my project. These are a great option for those of you who have welders and the ability to put this together. This is both the front and the back bumpers, although be patient with me I am limited by time and schedule with my friend that is helping me put these together. I want to add I am very thankful to him for the help, teaching and the shop for doing this project.
This is a new style for the 2004 body style. Elijah was kind enough to let me help him test the new bracket system out and to show everyone on here the changes he has made. The new bumpers use the factory brackets that are welded on the frame of the truck.

With the new design you do not need to cut the welds and remove these brackets as before. There were also a few changes with the overall look of the bumper, but it didn’t seem to be a major change to me. I do however like the new one better.
OLD STYLE

NEW STYLE

[strutindmax]

New style pic didn't work. Can you post a link to we're you bought the kit?

[Endica]

Ok so I didn’t get a good picture of everything as it was shipped. Here are a few pictures of the pallet that had all the goodies on it and a picture of all the parts up on the table as we are trying to figure out how everything goes together.




Once we got it all laid out and the front and the back parts all separated. We started with the center section. Found a center line and scribed it all the way up and down the front and back for reference throughout the project.



With the parts all cut and bent, there was little room for error. We lined up the ends and the bends and started tacking things together, starting with the two parts that make up the sides/ends of the bumper. Everything was about perfect and lined up without any problems.



The very ends of the bumper needed a bit of bending to get them to line up. This was very simple we did both ends differently and both methods worked well. First we clamped one down and used a large bender to get it as far as possible. On the second one, after tacking the two parts together we clamped it down and used the longer end to leverage and bend it into place.




We also used the crane to hold it in place as we tacked it. It could be done with clamps or having once person push and hold while the other person tacks it. I opted to take pictures and let the crane do the heavy lifting.

[Endica]

Originally Posted by strutindmax

New style pic didn't work. Can you post a link to we're you bought the kit?

Ok it seems to work for me but who knows. I got everything direct from Road Rhino (Elijah the owner)

Road Rhino | Heavy Duty Truck Bumpers

He sells them through Ebay. You can also just call him direct as I did. He was a little hard to get a hold of at first as he was very busy. After a bit he was very easy to get a hold of and responded to my email quickly answering all my questions.

This is a link to the front only but he does sell both together. Lists them at $895 for both front and back.

Road Rhino WIY Front Bumper Kit | eBay

[strutindmax]

Nice. Thanks a lot

[strutindmax]

I have been wanting after market bumpers like these but 2200 for a set is not realistic price for me. These might be a good Christmas present for me. Thanks again

[Endica]

Once we finished up with the ends we tacked them to the center. We found it best to build on the table upside down to keep everything level and give us some good reference points.







After we got all the main outside parts tacked up. We started on the interior parts and brackets. The main brackets that tie into the truck with four bolts that were provided (grade 8) are sitting lose in the picture below. As you can see there is a bend in the top of the bumper (sitting down on the table) that fits into the angle on the bracket. Once you get everything laid out it all fits together like a puzzle. Everything has its place. We simply lined up the bend in the top to the angle in the bracket, and made sure they are square to the front of the bumper and tacked it all in, starting with the top plate.





You can also see in this picture the notch in the front of the bracket. This is where the huge shackle mount will tie into the bracket that bolts to the brackets on the truck frame. Everything is tied directly to the frame and should be very strong.







You can see in this next picture how everything lines up once you get it into place. Keep in mind at this point we are still putting together the outside and have not yet checked the distance to our center line. Once we tacked all the outside together on one end and checked the distance it was within a 1/16th. A small adjustment and it was perfect.

[Endica]

Originally Posted by strutindmax

I have been wanting after market bumpers like these but 2200 for a set is not realistic price for me. These might be a good Christmas present for me. Thanks again

Yeah I was in the same boat. No way was I going to get $2200 for each. I scoped these out for a long time and ended up rear ending someone..

But I got a check from the insurance and only had to use some of my duductable to get both front and back

[Endica]

We finished up on a number of the details. Starting with the fog light mounts. We simply eyeballed these and tacked them up, adding a few extra tacks later to make sure they were not going anywhere. They will never have much force on them so we didn’t weld them all the way or even really stitch them in.



Here they are from the outside



Next we fitted the shackle mounts in. Again very easy, simply slid them in until they hit the bracket on the inside and held them as far to the inside as possible. Eyeballed them from the front and tacked away.





Here is a shot of the winch mounts tacked in. They are cut and bent and fit into place. We had to grind the top off a little to match up with the holes on the front. It was just the edges that flared out when they were bent.



I will get some more pictures and finish up the front soon. Hope you enjoy for now. Let me know what you guys think, I hope all these pictures are working for everyone. It's starting to look like a bumper!

[GLASSMAN JR]

I'm thinking about doing this for sure is there anyone I can actually talk to. That's not a bad at all for two bumpers


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