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Vanagon Bumper Fabrication

This was an awesome project I did during my time at UC Davis. I took two welding classes at learned how to weld with a variety of methods, TIG, MIG, stick, and oxyacetylene. This was my final project for the quarter. I saw a bumper I loved online and set out to build it myself. 

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I had to learn how to consistently work with 1 3/4" pipe on a manual non-hydraulic bender. How to fabricate this bumper around my car and got great experience with TIG welding. 

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I built the bumper piece by piece starting by attaching the mounting pieces to my car and building around them. Tacking each subsequent piece together as I completed the bends. For a top plate I used 3/16" diamond plate, cut to fit my car using a plasma cutter. Ultimately I liked the bumper so much I got it powder coated. 

bumper.jpg
Bumper Fabrication: Image
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Halfway done.

Tack welding each piece as I go. Getting consistent tight bends was a challenge. The steps I used are shown below.

Bumper Fabrication: Image

Learning to use the pipe bender.

Bumper Fabrication: Text
Bumper Fabrication: Pro Gallery
Bumper Fabrication: Pro Gallery
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Feeling happy. These were some of the greatest classes I took during my undergrad.

Bumper Fabrication: Image
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