Alright so I figured out that the 99+ ex bumpers looks great on but is just not functional off road. It just hangs down too low, and get in the way.(ask Jefe he knows:rolleyes: ) So I can but on a factory pre '98 bumper or just tube it!:D

Well lets just say this is the first truck I've had that I havn't ripped off the factory one and put a Pre-runner bumper..........yet:D

My question is 1.5" tube too small, or will it look stupid? I wanna use 2" but Mr Tim (TDG) only has a 1.5" die. He has offered the the use of his tube bender ;) But I don't have the mula for a 2" die and I don't think Tims gonna run out and buy one just because I wanna build something, nor do I think he should. If I do a front , I'll probally build a rear (maybe T-carrrier) and Sliders.

most pre runner bars I have seen look to be made out of 1.5" tubing. Ive seen a few with 2" but they were usually fullsize trucks. IMO i think 1.5 looks better. In the future i plan on buying a bender and i will get the 1.5" die and 1.75 before i would get a 2". But it is your truck so do what you want.

the fabtech ones for mini and mid sized trucks retail for around $175... these are sweet and are made of 1.5" tubing... it only seems to replace the lower valances but it is available with a skidplate and it looks as if it is structurally sound too.... not sure if they have an explorer application..... i plan on getting it for my yota

I plan to make mine out of 1.5" with the one exception of the horizontal bar going from side to side which i think will look nicer as a beefier 2" tube.

It will be some combination of these two.
Ricks grill guard portion, and everything except the prerunner hoop of the other.

http://www.jefethegreat.com/host_pics/pumpkin.jpg

http://www.jefethegreat.com/host_pics/pic5.gif

Of building one simmler to mine off my old ranger
http://www.jamesduff.com/images/readers-rides/12122003162019.jpg

The only thing I did not like is I could not push cars with it. The Hoop just stuck out to far and would go through anything first. But It was strong as hell!;)

and I'm think'n doing the bumpers in blue...What do ya think? White and blue?:rolleyes:

Mine's made outta 1.5 and it works for me. I just don't dig the 2"+ look unless its in a redneck 4by with a Texas truck bar. Those things are tight

Here's what I've got for mine so far: (I love AutoCAD :) )

Its one 2" piece, and the rest is 1 1/4".

http://www.jefethegreat.com/host_pics/front_bumper/front.jpg

http://www.jefethegreat.com/host_pics/front_bumper/top2.jpg

http://www.jefethegreat.com/host_pics/front_bumper/side2.jpg

Alright, so I finally ordered the bender dies (1 1/4", 1 3/4" and already have 1 1/2") for my front bumper. I have a few mods to make to my above design in my head. I've already got a winch on the way, so I'll start with the hidden winch mount this next weekend.

Howdy Jefe

I don't know if you've run across my pics yet....but I have something very similar to what you're looking to build. I recently mounted a Warn 9.5xp behind it and it fits perfectly behind the bumper. I can post up some more recent pics if you're interested at all.
http://www.explorerforum.com/data/500/17517new1.JPG

Howdy Jefe

I don't know if you've run across my pics yet....but I have something very similar to what you're looking to build. I recently mounted a Warn 9.5xp behind it and it fits perfectly behind the bumper. I can post up some more recent pics if you're interested at all.
Wow Sweet Thanks. :thumbsup:

Any particular angles you would like in the pictures? I have yet to go and take them...lol.

Any particular angles you would like in the pictures? I have yet to go and take them...lol.
I think the stuff in your gallery will be good enough for now. Thanks

No problem. I'll still try to get some up of the winch. I wanted to have more bends in mine like you have around the headlamps in the pictures, but the shop informed me that their dies could not bent the size tubing to that much of a degree. Other than that it's everything I've ever wanted. :D

Jefe do you have a nocher? I want to do mine like a ARB or TJM. Box bottom and tube on the top. That way when I do the rear and sliders, it will all match. I was goning to just buy OffroadKC's but I can't seem to get enough communication back and forth. Besides I'll be much Happier doing what I want. Besides I have a new option devloping in the SAS. ;) My dad want to buy a 78-79 250 or bronco cheap and snag the drivetain for his 80. and then I get the axles :D

Man that looks MEAN...nice.
Jefe nice CAD work :)

Stic-o I have the same bug....

:)

Jefe do you have a nocher? I want to do mine like a ARB or TJM. Box bottom and tube on the top. That way when I do the rear and sliders, it will all match. I was goning to just buy OffroadKC's but I can't seem to get enough communication back and forth. Besides I'll be much Happier doing what I want. Besides I have a new option devloping in the SAS. ;) My dad want to buy a 78-79 250 or bronco cheap and snag the drivetain for his 80. and then I get the axles :D
Too bad yer on the other side of the country, thats the type of bumpers i'm planning on building soon

Jefe do you have a nocher?
Thats also part of the Pro-tools order :)

Besides I have a new option devloping in the SAS. ;) My dad want to buy a 78-79 250 or bronco cheap and snag the drivetain for his 80. and then I get the axles :D
Sounds like a plan.

which bender/notcher you have/are getting? I just order my bender and notcher and junk 2 weeks ago

which bender/notcher you have/are getting? I just order my bender and notcher and junk 2 weeks ago
I have the Pro-Tools 105HD bender w/ degree ring and I just ordered their heavy duty notcher and it is on its way.

I have the Pro-Tools 105HD bender w/ degree ring and I just ordered their heavy duty notcher and it is on its way.

nice how do you like that thing? I orded the 105hd package w/ the works and the hd notcher as well (didnt like the idea of the one with a sticker for the degree marks)

nice how do you like that thing? I orded the 105hd package w/ the works and the hd notcher as well (didnt like the idea of the one with a sticker for the degree marks)
To tell you the truth, in the year I've owned it I've made two bends with it. :rolleyes: But it worked great for those two bends ;)

To tell you the truth, in the year I've owned it I've made two bends with it. :rolleyes: But it worked great for those two bends ;)


Sound like you some help.. :p

I fabbed up my winch mount yesterday and just finished wiring it up:

Jefe, looks pretty good so far. Keep us posted with pics :)

Wow :eek: you been busy!

I fabbed up my winch mount yesterday and just finished wiring it up:

Most people cut holes for the rope to go through..

Hawse or roller fairlead?

Hawse or roller fairlead?

Hawse, you cant use a roller with the synthetic winch rope :nono:

Most people cut holes for the rope to go through..

Hawse or roller fairlead?
yeah yeah. I ordered an aluminum hawse fairlead with the synth. rope but it hasn't come in yet, so i didn't know how big my hole should be.

My bender dies finally came in this week. So I went and bought myself some metal and started bending . . .

And the mostly finished product:
(still needs a second set of mounts to the frame, light tabs, and one of the 1 1/4 tubes needs to be rebent as its almost an inch off, and then painted.)

Which winch is that? Looks good.

Which winch is that? Looks good.
SuperWinch - (and he's already used it, but that's another story!)

Very Nice!!!! I wanna run tube like you did on the top on my new bumper.

Now you can replace the fenders :p

:eek: That looks awesome! Nice work Jefe. :thumbsup:

Thanks guys, Even I was surprised at how well it turned out.

Very Nice!!!! I wanna run tube like you did on the top on my new bumper.

Now you can replace the fenders :p
Come on over. I've got enough tube to do it again (in case I messed up)

I was actually thinking about doing some body work to that fender, but I think I'll keep it that way. Afterall chicks dig body damage :D However I will be replacing my corner lights since both of them are being held together with duct tape. So I got in on the diamond corner group buy. :cool:

Thanks guys, Even I was surprised at how well it turned out.


Come on over. I've got enough tube to do it again (in case I messed up)

I was actually thinking about doing some body work to that fender, but I think I'll keep it that way. Afterall chicks dig body damage :D However I will be replacing my corner lights since both of them are being held together with duct tape. So I got in on the diamond corner group buy. :cool:


I got to get the bumper on first. Probally in a few weeks. I have to make mounts. It's probaly gonna sit on top of the frame, for now

. . .It's probaly gonna sit on top of the frame, for now
That'll probably look best for now, considering the bodylift

nice work on your x jefe i like it

Jefe - Looks AWESOME!! Good Luck!

wow...that looks awsome

Here it is nearly complete. :cool:
Just need to redo the pass side 'wing'

looks good Jeff

That looks great Jefe! Now people are gonna ask you to build them one :p

I have to get my new bumper mounted soon.... I got a ticket today for no front plate :mad: O'well I guess I can't complian really, I havn't had a front plate on any of my cars. So once in 10 years ain't bad :rolleyes:

Jefe,
Looks great! Why'd you keep that extra part of the main tube going to the wheel well? Are you going to fab something to match for the rear?

Jefe,
Looks great! Why'd you keep that extra part of the main tube going to the wheel well? Are you going to fab something to match for the rear?
The main tube wraps all the way to the wheels to protect the fender.
As for the rear, no tube bumper is planned. I still like my stock bumper w/ tire carrier better than any other bumper I've seen.