Custom front steel bumper?

[Ludachris]

Since I drive the car on the street I don't want to remove the steel bumper altogether. And I'd be a little worried removing it at the track since there would be no protection for me or the engine bay. A 5 mph crash would be devastating.

So I've been thinking about having a smaller bumper made up using some round tubing or square channel. I know it might end up being a little expensive since you'd probably have to cut it in 3 pieces and welded in order to form the necessary angles but the advantages would be:

- lighter weight in the front
- more potential access to cut holes and allow airflow to the radiator/fmic
- lighter weight
- it would take up less space

Anyone tried this?

[spoonman]

I was going to try this on my car by taking a large diameter steel tube, 3 inches, and welding to the mounts which hold the oem bumper to the frame, the cylinder like things. Then all you would have to do is drill some holes on top for the bumper to mount to. This would also be better in a crash because the the tube would slightly bend or crush itself in while the steel bumpers just move back on their mounting shafts and have very little give. This would help absorb some of the energy from the crash.

[tsiboosted]

I thgouth about taking mine out altogether as well. But for the same reasons (almost) you described is why I did not. I will sacrifice that weight in order to keep the engine bay and myself a little more safe in the car on the track. Would be interested to see if anyone else has come up with any ideas such as this.

I dont see why it would be too expensive. Time consuming maybe to get the angles right. But if you are working with steel here, any welder worth his job would be able to throw some welds on it for you I would think. But maybe I am wrong here.

[Ludachris]

Would you guys think it would be stronger to have a square tube cut and welded to get the right angle or to bend a round tube piece of steel? I'm just not sure if bending it will compromise the integrity of the piece. I would think it would be similar to a roll bar wouldn't it?

Here's what I think would be the ideal solution - take a length of steel bar used for roll bars/cages, bend it so it curves the same as the factory bumper. Weld on the short legs from the old bumper that connects to the frame of the car. Then weld on some tabs for the bumper cover support or just drill and tap the steel bar if it lined up correctly. Wouldn't that work? I'm just not sure how much weight that would end up saving. JMFab says the stock bumper weighs 35 lbs. I'm guessing maybe 10-15 lbs.

But hey, even if it didn't save a ton of weight it would still give us more space to work with and more potential cooling paths.

[tsiboosted]

Originally Posted by Ludachris

Would you guys think it would be stronger to have a square tube cut and welded to get the right angle or to bend a round tube piece of steel? I'm just not sure if bending it will compromise the integrity of the piece. I would think it would be similar to a roll bar wouldn't it?

Here's what I think would be the ideal solution - take a length of steel bar used for roll bars/cages, bend it so it curves the same as the factory bumper. Weld on the short legs from the old bumper that connects to the frame of the car. Then weld on some tabs for the bumper cover support or just drill and tap the steel bar if it lined up correctly. Wouldn't that work? I'm just not sure how much weight that would end up saving. JMFab says the stock bumper weighs 35 lbs. I'm guessing maybe 10-15 lbs.

But hey, even if it didn't save a ton of weight it would still give us more space to work with and more potential cooling paths.

I think the "roll bar" idea would work out the best. And that material can be bought for fairly cheap. Easy to bend as well if you/they have the machine to do it. You would probably save; like you said Chris, about 10 - 15 lbs. But the room that could possibly be gained would more than be worth it too.

But to me, I think the roll cage type bar would be better instead of trying to figure out angles and weld them with square peices of material.

[talonTSIDriver]

just dont hit anything and then you can take it out all together.

[tsiboosted]

Originally Posted by talonTSIDriver

just dont hit anything and then you can take it out all together.

Easier said than done sometimes I'm afraid.

[Zero Bar]

I like the idea. Round tubing would seem the best to me than you could add on what you needed for plate mount, intercooler, or whatever. The weight savings and the room added I think would be well worth it.

[Ludachris]

Originally Posted by talonTSIDriver

just dont hit anything and then you can take it out all together.

Where do I sign up for the "perfect driver/perfect drivers all around me" mod?

[talonTSIDriver]

Originally Posted by Ludachris

Where do I sign up for the "perfect driver/perfect drivers all around me" mod?

You didn't get that memo?

[talonTSIDriver]

What if you cut up your stock Front bumper support like this guy did on his 1g? This would still add some strength, and if you wanted, maybe add some 1/4in thick steel to strengthen it up.

[Ludachris]

It would be cheaper that's for sure. But I think a bar would be stronger and would give us more space.

[talonTSIDriver]

Originally Posted by Ludachris

It would be cheaper that's for sure. But I think a bar would be stronger and would give us more space.

I would call up your local machine shop or someplace that does roll cages, take them your stock bumper support, and tell them you want this in chromoly. I am sure they could fab something up for ya fairly easy. Should be much lighter and just as strong.

[tsiboosted]

Originally Posted by Ludachris

Where do I sign up for the "perfect driver/perfect drivers all around me" mod?

Yeah no joke on that one Chris.

Originally Posted by talonTSIDriver

I would call up your local machine shop or someplace that does roll cages, take them your stock bumper support, and tell them you want this in chromoly. I am sure they could fab something up for ya fairly easy. Should be much lighter and just as strong.

Thats what I was thinking/saying earlier in the thread. I believe if you went with the "roll cage" type material on this. That would be the best place to go. They would have all the material and tools to do the job "right".

[Droptop Spyda]

Thanks for the pic talonTSIDriver. If any one else has pics of custom bumpers post them up. I too am thinking about doing something different for my VIS Cyber bumper and FMIC.

[eclipsh]

I wonder if we have some engineers on the site who could figure out how much "swiss-cheese" style removal you could do to the factory bumper without severely compromising its integrity. I'll bet you could do a lot to the faces so long as you left the top and bottom intact.

Otherwise, what about doing two small diameter (2") pipes across the front, truck style? Heck, leave the bumper cover off and do it up Baja style

[tsiboosted]

Originally Posted by eclipsh

I wonder if we have some engineers on the site who could figure out how much "swiss-cheese" style removal you could do to the factory bumper without severely compromising its integrity. I'll bet you could do a lot to the faces so long as you left the top and bottom intact.

Otherwise, what about doing two small diameter (2") pipes across the front, truck style? Heck, leave the bumper cover off and do it up Baja style

I never thought to look at some baja off-road style truck bumpers to get some ideas like that. Good thought man. At least it would be something to design off of for a fabricator you know?

[mitsocruiser]

if someone can tell me how to post a picture I can show you were I have a steel bar welded on the front of my car and can still get a bumper on fine