Custom Bumper

August 30, 2011



Given that I had been running bumper free since some time in 2008, I had finally come up with a complete design for a front bumper that would replace the tired and faded aluminum one. This bumper used new formed brackets that bolt to the frame (they almost fit; I will revise the design so the holes sit further back… I had to ream out my frame holes). The body of the bumper is of unitized construction, all built into one piece, making it stronger. The tow hook tabs are mounted as high on the bumper as possible to allow for a more aggressive approach angle, and are directly in line with the frame rails for added strength when pulling (as opposed to being pulled, which should never happen).


I had completed the CAD work for this design 3 weeks prior, and had sent it off to the fabricating shop for a quote. In order to build it to my design the front middle section (with the tow hooks, and the wrap under below it) would have to be built separately and welded in, with the weld running along the leading edge of the bumper. This wasn’t a big deal, except the edge wouldn’t be that nice rolled form it would have been from a machine. All said and done this bumper cost me $350 (unpainted), which when compared to the $600-$800 price tag of bumpers from other aftermarket manufacturers, seemed like a pretty good deal.

I was able to mount it with relative ease, with the help of my parents to hold it in place while I fastened the brackets and the bumper to the frame. The fit was good, with a bit of filing to get the frame holes in the right spot. I had planned to paint this at the same time as the rest of the truck so mounting it meant I wouldn’t have to carry it up in the back.

This bumper certainly gives the truck a more aggressive appearance, and makes it look like it belongs to a 23 year old as opposed to a 63 year old (who would suit the woodgrain and rubber bumperettes). I’m not as opposed to that plastic grille, but would still prefer something off an older rig, with round headlights. I plan to paint it satin black, so at least it looks like powder coating (though hopefully it doesn’t behave like powder coating).

Giving it the Once Over

August 23, 2011
 Sit Rep: There are a few faults it must be said; the engine leaks oil, the tranny leaks fluid, the radiator is on borrowed time, the clock disappeared, the AC is disconnected, the rear view mirror has fallen off 4 times, and my left rear door lock is sticky. That being said I can live without AC, I can manually unlock 1 door, and I can look at my watch. The leaks I will have to fix before they turn my driveway into a tar sands. With winter coming on, my radiator will last me until the spring so I have shopping time (replacements are $800, re-core’s are $300).


I took the truck for a bit of a spin up into the countryside north of where I live, to test out the systems on some quieter backroad routes. It’s a fun drive; being in something much older than other cars on the road. There is a sense of nostalgia as you look past your non-airbag steering wheel out over the large hood with a chrome ornament perched atop it; very non-Kia.

I snapped a few Camera Phone pics of it parked at an old school house. I realize the patchwork of paint, primer, bondo, and steel make for an interesting look, but that will soon be gone, along with that out of place bumper which I took off when I got home.

Becoming Legit

August 23/2011

It's like walking into the hall full of students waiting to write their passing exams, knowing that everything you have spent so much time on will be judged in a quick, thourough proving session. I felt the same kind of anxiety that I'm sure artists feel when they release an album, or a designer pitching a product on Dragon's Den.

This anxiety was justified for a few reasons. If the wagon failed the safety it meant I would have a list of yet more things to fix - to spend money on; not to mention the cost of another safety test. I had never tested the emmissions systems, only fixed what I had found to be dysfunctional. on top of these things was compounded the pressure of getting it certified so I could drive it up north to the waiting paint booth so I could paint it before the weather got too cold. I had booked a week of holidays months in advance so I was locked in; whether I spent them painting or I spent them fixing stuff I missed.

Lets just say the vehicle found it's way to the dealership in an undisclosed, yet fully legal manner. This provided a good test to see how it felt hitting 80 for the first time in nearly 4 years, and allowed the cat to heat up enough for the etest. upon arrival I hopped out, and my brother in law wheeled the big beast into the shop and onto the dyno for it's etest. While I wasnt allowed in the shop for thie following procedures, My brother in law had my camera-phone for some shots during the safety test. much to my surprise it passed the test by the skin of its teeth on the first round. I can probably attribute this near miss to its lack of use over the past few years (as i write this in November, it runs much better)



Looking to design a "Back From the Brink" sticker for the window to signify just how close this thing was to the crusher.

Sitting in the showroom with all the brand new baby Subaru's while my Senior Citizen Jeep towered on a hoist in the shop felt very numb, almost clinical; the way a father waits at the hospital for their child to be born. I was yet again surprised when after maybe 25 minutes my bro in law came out to tell me it was all finished, passed and certified. I was then able to go into the shop and snap a few pictures. I then settled up all the legal stuff and bills and set off in search of a licensing beurau to get some plates (another anxiety inducing task).



This thing weeps for paint, though the patchwork effect lets you know this vehicle has seen some pretty significant battles.



Note the orange Brakes for added stopping power



Apart from the lineup, the MOT deal was pretty uneventful, and I got the industry's only friendly and helpful assistant. I wont say any more about that since it's so boring, but I got a set of plates, Returned to the dealership, and popped them onto my newly legal beast.

Continued Next Post...