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Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
Vanther #571601 June 29th 2012 4:22 pm
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So all the brackets, studs, plates, and pieces are all drilled for all those big 3/4" size bolts.[Linked Image]
[Linked Image]

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.
[Linked Image]
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.
[Linked Image]
All the bolts are waiting, and ready to finally go back together.
[Linked Image]


[Linked Image]
Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
Vanther #571605 June 29th 2012 4:26 pm
Joined: Dec 2003
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That's going to look great.


Shanning P.
Alberta, Canada
[Linked Image]
1991 Dodge Ram 250
Member of Vandits VC. Calgary
Stay Weird!
Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
Vanther #572166 July 02nd 2012 11:54 pm
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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.
[Linked Image]

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

[Linked Image]


[Linked Image]
Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
Vanther #572170 July 03rd 2012 12:48 am
Joined: Jun 2009
Posts: 1,170
M
M_S Offline
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M
Joined: Jun 2009
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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.

Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
Vanther #572171 July 03rd 2012 12:58 am
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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.


[Linked Image]
Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
Vanther #572174 July 03rd 2012 1:04 am
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Here is the final bolt insert showing the clearance of the main D ring pin.

[Linked Image]

[Linked Image]


[Linked Image]
Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
Vanther #572310 July 03rd 2012 5:38 pm
Joined: Jul 2003
Posts: 822
Likes: 1
X
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Nice project you have going there! I happen to be fan of A- Team vans (done right). The new movie version is pretty sweet. I hope everything turns out like you want. Good luck with it, and hope to see it when it's done.


X-MAN
[Linked Image from img.photobucket.com]

Looking forward to the next Truck-in!


Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
X-MAN #574968 July 19th 2012 10:01 pm
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So I just got the winch wired up. Ran 4 gauge wiring all to the interior for a remote battery.

So, I have a heavy duty isolator to separate the starting battery and the remote deep cycle gel cell battery (150 cold cranking amps).

So now I will run the aux wiring from the remote battery to the roof light bar, and the front two pairs of driving/fog lamps.

For the winch, I brought the switch inside the dash up to the left side air vent - and I'll just make a little plate to control from inside for the convenience.

Wiring up remote switch later for keychain use.

Pics soon!


[Linked Image]
Re: Installing custom Bull Bar/ Brackets/ Tow Hooks
Vanther #578956 August 14th 2012 3:29 am
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Picked up the bumpers this weekend, had everything all finished up in a gloss powdercoat black. It looks amazing.

Just bolted everything back on with new stainless hardware, gave the van a nice sunny wash, and finished bolting all the brackets, hooks, fairlead, hook, and lights on.

Im perfectly happy that after all this time (1 year 3 months) it is finally finished. Took a lot of a lot. Time, work, money, everything- but it turned out just how I wanted and the first time I hit the store with her black and sassy, people were asking me about it and complimenting how nice the van looked.

Here are some pictures of the finished piece...

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


[Linked Image]
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