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Building the Official Prusa Printer Enclosure out of Ikea Lack Tables
Scale License Plate
Metal Rose
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Slip Roller
Staübli Reborn: Industrial Robot with a Modern Control System
Full Suspension Mini Bike
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First Welding Project: Making a Weld Cart
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Bronco Bumper

2024-4-30
Projects
Tig
Summary:
  • Fabricated custom front and rear steel bumpers with integrated shackle mounts and receiver hitch for a Bronco
  • Built a custom grill panel using dedicated jigs and fixtures to ensure repeatable alignment and fitment
  • Iterated through multiple fit checks and metal bender passes to achieve precise clearance around shift knobs, lights, and body panels
  • Designed and machined mounting hardware including shift-knob bores, enlarged access holes, and light cutouts with structural reinforcement

00-metal-bumper.jpg

01-determining-location.jpg

02-lil-fixture.jpg

03-adjustable-line.jpg

04-split-before.jpg

05-split-after.jpg

06-it-fought-back.jpg

07-metal-split.jpg

08-test-fit.jpg

09-shift-knob-alignment.jpg

10-shift-knob-drill.jpg

11-shift-knob-bore.jpg

12-shift-knob-install.jpg

13-drill-mount-holes.jpg

14-nasty-metal-enlargement.jpg

15-test-fit.jpg

16-clearance-detail.jpg

17-bend-attempt.jpg

18-bend-success.jpg

19-test-fit.jpg

20-weld-detail.jpg

21-another-weld-detail.jpg

22-complete.jpg

23-test-fit.jpg

24-large-socket.jpg

25-rear-bumper-test-fit.jpg

26-receiver-hole.jpg

27-shackle-design.jpg

28-shackle-design-fit-test.jpg

29-shackle-blanks.jpg

30-rear-fit.jpg

31-light-hole.jpg

32-light-hole-birdsnest.jpg

33-rear-complete.jpg

34-mini-bike-fit.jpg

35-selfie.jpg

36-front-bumper-fit.jpg

37-notching.jpg

38-grill-part.jpg

39-grill-fixture.jpg

40-grill-complete.jpg

41-sick-bronco.jpg

42-of-course-a-winch.jpg

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3D Printed Drones Upgrading Shop Air Compressor Aluminum Mountains Layered Backup Workflow Bosswatt Prototype
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