This is my new project. I've got the tig, the cutting tools, sander, etc... I found the basic steel design photos but was wondering if anybody had any input. I was also thinking if I made one I might as well make two. Whats a fair price for a good aluminum bumper?

Wish I had a TIG welder. I plan on doing mine in steel. Hopefully can make it look good, too... Make sure to post up pics!

I always wanted one that had good style, following the contours of the truck, without the heavy austrailian outback look. I would like diamond plate on top for standing on to do engine work. A couple tow hooks, fog lamps and probably no brush bars or at least of minimum of bars.Might be cool to have a lockable compartment for the jack and tools.

All I can tell you is yes you bumper will be lighter than steel. But it will most likely cost more that steel.I'm really curious what you built tho...

I know that the Aliarc aluminum bumpers look nice but for actual long term use they do not hold up, I have several friends who used to run them and over time of running country roads they crack out and rattle themselves apart and if one does hit a deer with them they will somewhat protect the rig but the bumper is all but good for the recycle bin.BNSF railroad used to run the Aliarc bumpers on every crew transport vehicle and has since gone away from them for the same reasons, they do not hold together and are always in the weld shop getting fixed.I know there are other brands of aluminum bumpers like the Australina company UTE bull bumper that are made quite heavy and hold up better but are cost prohibitive, I will stick with my Ranch Hand steel bumpers, best bang for the buck litteraly as I have made it a bad day for many deer with mine over the years and no damage to anything at all.I think ARB makes a heavy duty alum bumper too but very expensive as well.

All I can tell you is yes you bumper will be lighter than steel. But it will most likely cost more that steel.

I'm really curious what you built tho...

Well, it hasn't been built yet, but I am hoping to make it a summer project. The band saw should be operational soon and the tig welder just got the rest of the equipment to get rolling.

I haven't worked with aluminum a whole lot, but here is my biggest project to date. I did 90% of the welding, and probably 50% of the coping. 4130 very thin wall tube, .091 was the thickest, and did some aluminum for it. I am sure I can figure it out though and want to be able to do Al with the welder. I can't say I am a great welder, but I used to be pretty good a few years ago and I am sure I can pick it back up.

jig for our front spindles

The welder I have currently... AirCo (same as Miller DialArc 250) it's an old solid state non circuitboard TIG. Not as nice as a new square wave, but very reliable and very smooth. Plus, it has high and low range, with a gear shift!

I know that the Aliarc aluminum bumpers look nice but for actual long term use they do not hold up, I have several friends who used to run them and over time of running country roads they crack out and rattle themselves apart and if one does hit a deer with them they will somewhat protect the rig but the bumper is all but good for the recycle bin.

BNSF railroad used to run the Aliarc bumpers on every crew transport vehicle and has since gone away from them for the same reasons, they do not hold together and are always in the weld shop getting fixed.

I know there are other brands of aluminum bumpers like the Australina company UTE bull bumper that are made quite heavy and hold up better but are cost prohibitive, I will stick with my Ranch Hand steel bumpers, best bang for the buck litteraly as I have made it a bad day for many deer with mine over the years and no damage to anything at all.

I think ARB makes a heavy duty alum bumper too but very expensive as well.

Thanks for the input on that... Depending on the price of the Aluminum plate, I may still go steel. However, I think I can design a system that will be rugged enough for my use. I do understand that Steel is always more better if weight is not an issue.

Mainly, I just want to try making one in Aluminum. I want to be able to make the old miller TIG do the stack of dimes that I can make it do with steel. Kind of a personal challenge, so to speak. It would also look great with my two tone blue/silver 2nd gen.

:2cents:Go with heavy steel and put some sort of bedliner on it.That'll be what I do... Al's Liner!

Cpp has a kit

I think depending on how you build it aluminum could be pretty strong. Especially if you build the bumper with 6" or 8" channel $$$$ or if your just looking to do alum plate you could possibly build the frame mounts and a skeleton with carbon steel and plate it with aluminum (or stainless ). I do alot of work with 304 and 316 SS pipe and actually priced some Sch 40 2" and some 6" SS channel a while back maybe some day if I wind up with pockets of money with nothing to spend but lets just say its not going to happen anytime soon