Making custom bumper, suggestions?

[dunerinaz]

I started machining an aluminum bumper at work today. It only took a few minutes to get a basic shape. Don't look at placement in the pictures. It's only sitting on the bumper mounts. I'm working on a Dynamic Concepts body so it will be mounted to fit that body.

Any suggestions on how to finish it? I'm thinking of doing a cutout on top in the center for a winch like some 1:1 bumpers are. I will be doing a stinger as well. Not a big one but haven't decided on a final shape yet. I do know that I'm not going the normal route and welding it on top. I'm going to drill holes all the way through at the angle I want the stinger to be at and plug weld it on the bottom. That way I can grind it flat on bottom and melt aluminum rod around the joint at top for a clean look and much stronger. Still trying to decide on how to mount lights as well. I may just forgo the lights and do a lightbar on top later.

[crazy81]

Looks good so far!

Do some recessed lights, like a Dingo bumper or 1:1 truck bumper.

[KillerBlackbird]

Like crazy said, maybe something like this:

[gec]

And mark out the shape of an Aluminum Winch Fairlead, then machine around it so its part of the bar.