95 suburban 4x4 build

[martischangcarl]

Hey proble wont get a chance to call tonight but looking good exsept for that hugh gape. If you have enough estra light gage plate i would fill it and wrap it in a way like the guy fro aussi with the geo tracker did. it would give the rear bumper some sort of lines and make it look good. It dont have to be dimod plate cuz i know thats hard to come by and not cheep if you have to buy it but you can just use some smooth flat steel I wish i could drow on the pics. send me some close up wide side shots of the bumper and some top wide shots and a good straight on rear shot I will try to draw on it in the paint thing and email it back to you. I would use some cardboard and shape it as needed so you can weld it off the truck. or tack it and then take it off. up to you. wish i was there to help with the fabrication. Sorry I cant talk on the phone much somtimes, I get busy or I am doing somthing with the wife!!!!!

[josh25]

Well for now I'm only covering the gap from outside of frame to outside of frame I will use some rubber to hang underneath the body to cover the body mounts. After looking at it today I kind of like it sticking out like it does. I believe it will add some good protection keeping stuff from getting to close when backing up on trails etc. Also I don't think it will look to bad once I fab a spare tire/fuel can swing gate for the rear. I believe with it sticking out like it does it will make mounting that easier and that swing gate will hide the gap. So we will see how this looks once I get it painted black and on the truck. It's only metal I can always change it latter when time permits and I have a different idea. For now I think it's awesome having a humvee rear bumper, haven't seen anyone else with this.

[Da Burb]

I agree.....I'd sheet it first and then mount the wheel carrier on it.

[josh25]

Ok so I got all the prep work for paint done today and shot one coat of Shermin Williams DTM black on the bumper and bracket. I also got the passenger nerf bar off, I trimed a inch off the front for tire rubbing and got it prepped and one coat of black on it also. Here is some pics.

[josh25]

I've got one more coat on the nerf bar that is standing upright then it will all be finished painted. I plan to let it sit for a few days before I reinstall all of it back on the truck. I will probably put it all on on Sat or Sun.

[josh25]

I also got a cb radio from a buddy of mine so I plan to put the antenna on the rear bumper and make a box to hold the radio at a angle on the center hump between the dash and console. I want to build the box to also hold a extra 12volt plug and have a cup holder in it. I got the idea from a thread on here that a guy built one to hold his airbag controls and ac controller in. He also used a cheap cupholder that I found here at the local auto part store. I will try to do something similar.

[josh25]

Well here she is, I have plans this weekend so I decided to mount it all up tonight. I have to mount the liscense plate tomorrow correctly and also mount my trailer plug. I also have to do a few touch ups on the bumper, enjoy.

[Big~Kenny]

Looks good!! Id hate to see the aftermath of someone who rear-ends u...wouldnt be pretty.

[josh25]

So after taking her on a 300 mile exhibition with the family and then mud riding about a week later and hitting the high pressure hose at the car wash I have to do some touch up painting on the nerf bars. I guess it just hadn't had a chance to cure. The bumper has a few scratches from my boot but otherwise no blemishes on it what-so-ever. Has anyone ever tried taking apart a tail light like I have to paint the chrome in it black? I was considering trying to do this I don't like those tailights at all.

[bonedust]

without an etching primer, paint isnt gonna stick real well to bare metal.

[josh25]

The nerf bars are aluminum, I used alumi brite on them then sanded some of the kinks out of them and shot it with a light coat of primer, then lightly sanded that back smooth. Then shot the black dtm. I will redoe them when I build the front bumper if I get to. If not no big deal I use it and it's going to get marked up so it's no big deal. I am pleased at how well it held up on the bumper however like I said the bumper had a extra day to cure and had two coats of primer plus it was metal not aluminum so I guess those things played a part into it holding better.

[Ivan D.]

Originally Posted by josh25

For the front bumper what size and kind of driving lights do you guys recomend? I need to get some soon so I know how big of holes to cut out. I also can't decide if I want to do a bar on top like a brush guard or just one like the one in the photo that was cropped for me.

Here is the cropped photo.

I actually like how this bumper looks on your truck, needs to be black of course tho. As for lights, those 6" or 7" round ones don't look good at all, maybe four of the 3"x5" variety? That's what I got on my dually, 100W bulbs light up the road like tis a sunny day - mine all have spotlight lens, but in your case I think it'll be better if you go for two trapezoids in the middle and one flood on each side, then use your larger in-bumper lights as spots and the smaller in-bumper lights as fogs...

[josh25]

I just thought of something I plan on possibly working on my front bumper Mon. How will the airbag sensors be affected when I build my front bumper or will they be affected?

[hoseman44]

back bumper looks great the only thing i would do is probably cover the gap between bumper and body but other then that looks reall good. when you redo your step bars hit em with some bulldog adhesion promoter that might help or powder coat them if you can

[Ivan D.]

Originally Posted by josh25

I just thought of something I plan on possibly working on my front bumper Mon. How will the airbag sensors be affected when I build my front bumper or will they be affected?

trace the wiring and find where these are located in the stock bumper, then install them in about the same area behind your new bumper. IIRC these are little 2-axis (or maybe even 1-axis) accelerometers, they don't rely on any crushed metal to be activated and trigger the airbags, many cars even have them installed way up behind the grille.

[josh25]

Ok so I made a little progress today. Mostly unbolted the old bumper and set up all the weld/cutting equipment up at my house. Also had to shovel the snow out the driveway prior to begining. I didn't start any fabbing until about 3pm so I only have two brackets cut and grinded. The plasma cutter won't cut this 1/4" plate so I have to use the torch then grind it straight and smooth as I can. I will post pics as I get them. Another day off tomorrow so hopefully I will be able to get a early start and really get some progress done. Also since I can't use the plasma I will not be able to build it like the photo shopped image above is done. I will try to draw my design out on the computer and post it a little later if I can.

[josh25]

Just a update you all won't want to hear. I had to pull back on making my front bumper for now. To many things going on at the moment and not enough time. I'm trying to get my family moved and I'm getting ready to transfer and Xmas ran up to me so I will just hold off on it and build it later on or buy one. I will not be able to do any fabbing at all for the year or so for I will be to busy at my new job. Right now my front in sits with no bugshield I ditched that pos, I may buy a new one that matches my ventvisors, and I haven't put the brush guard on. I'm undecided if I want it on or not. I like the added protection and the fact they held my driving lights, but those lights recently got messed up so they don't work anyways. However I also like how I can more easily clean the front without it being there.

I did change my O2 sensor out today, the old one was jet black. I also changed my fuel filter and I picked up some pretty nice mud flaps. I'm supposed to have mud flaps since I'm lifted but I haven't put any on yet I will try to mount them tomorrow and will post up a pic after I'm done. I also picked up this step that bolts up to my ball mount that allows easier access to the cargo area. It came gray and I painted it black to match the rest.

So what do you guys think ride with or without the brush guard for now.

[josh25]

So today my passenger cv axle broke 100 miles from my house. After firestone said they would replace it $520 bucks I elected to creep home and do it myself. I've already changed it out tonight, it took 2 hours cost me 100 bucks for a brand new one.

[Ivan D.]

Congrats on the repair. Also, a heads-up, if your rear U-joints ever let go, you may be able to nurse 'er home if you lock in the 4x4 and drive like tis a FWD.

As for the gill guard - man, tis winter, there is deer out there, also snow, ice, black ice, and lots and lots of stupid drivers - put that thing back on, better safe than sorry ya know.

[josh25]

I'm thinking of painting it black this weekend and putting it back on this way it matches the black nerf bars and rear bumper. For that exact reason, added protection.