Front Bumper

We wanted a big looking bumper to fit with the over sized box and to give the cab a more aggressive look. We added 9" to the bumper to get it to fit to the outside of the fenders. 

Chris used 1/4" plate steel and cut it to size for each of the profiles of the bumper.

Then he and shaped the 1/4" stock to the bumpers profile. 

Next up was to make some mounting brackets. We incorporated the bumper bracket with the sway bar bracket, but fabricate a new sway bar bracket to hold the extra weight. We still used the stock location and also used larger hardware.  

Used 3/8" x 3" bar stock for the bumper brackets and used a mechanical brake to get the shape that we wanted. Before we bent our brackets we made templates out of  3/8" square bar to get the shape we were looking for.  

We also machined three slotted holes for some adjustment if needed.

The first test fit.

Getting things all leveled out.

A look at everything mounted up.

We also finished the ends of the bumper to give it a more solid look.

Had to put in the mocked up grill to get the over all look. Still need to fill in the old mounting holes that we didn't use.

And some photoshop work.