Just dropped off the van this weekend to fit and finish the mandrel bent piping at a guys shop here in town who does roll cages etc, on the mandrel bender he has.

I went over the pics, angles, bumper etc, and he seems to feel very confident it will turn out right.
So he had to take my old chrome one off, fit the new primed black one, then weld and fit piping to make sure it all lines up.
I am seeing if he can fab up a new crossmember/radiator support to increase the 4" gap behind the bumper to fit that Warn winch I picked up. That way its frame mounted and still functions to a degree of non embarrasment as opposd to all that work for a static display. Plus I like buttons.

Then after it is all pretty I will have him take the front and back bumper off and send it to the sandblaster/powdercoater to match the light bar.

Then, its on to saving up enough to drop the whole piece off to get painted. After I fit and finish the flares.

I'll keep you guys posted and get some pictures to you ASAP. If it doesnt cost too much to do the whole spread, Ill have him install the sidepipes too.

Bull bar is done up and finished, all welded and fitted.
Got the winch installed and mounted. Took some negotiating the radiator support to finish it, but welded a reinforced box plate between the frame rails, with an extended cut out on the passenger side to allow operation of the free spool clutch. Painted the welds and new metal to prevent rust.

Next is the rear bumper chrome stripping (which is in the back of my van) and touch ups, then off to the powder coater.

The front just needs a 3/4" hole through the bull bar supports to bolt in the reciever stye tow hook insert piece before the powdercoater finishes the entire front and I can bolt it up and wire in and finish the winch hook install.

Finally- A year and two months later... Just finishing it all up.

And as an exciting upcoming development with my licensing- "Vanther" will be my new plate =)

Very cool.

Thats gonna look mean!

So all the brackets, studs, plates, and pieces are all drilled for all those big 3/4" size bolts.


It took a lot of work to drill some of them, 4 different size bits, as I couldnt put the bumper itself on the bench to drill it (hindsight and rushing things...). Last is foglight holes, before powdercoating. and then reinstalling.

I dropped off the back bumper today to get it touched up in appearance and chemically stripped, plated, and then off to the powder coater.

All the bolts are waiting, and ready to finally go back together.

That's going to look great.

So final part back for the front end, buddy and I machined the end caps to fit under the crossbolt of the tow D-ring.


There is about 2mm between the main bolt and the machined one. So now, it will all fit.

The two best tools I have purchased, besides a floor jack, were a lathe and mill. You never know how much need there is for them, like this bolt head, until you have them.

I have been taking full advantage of machining friends and taking care of them for their help for that exact reason. Even on this project, some things just have to be made, milled, or turned down, and there is little option to buy things like that bolt off the shelf.
Plus its been lots of fun actually making something, you know is unique to your van.