Making your own HD bumper... thoughts?

I had an idea... I know where I can get hold of some scaffolding poles, and thought I might have a go at fabricating my own HD bumpers...

Question is, are they up to the job? I belive they're 2" OD (standard scaffolding size?) and the plan would be to weld 2 together, one on top of the other, and either cut 'n weld or bend (if possible) to mimick the slight angling back of the commercially available ones - and, obviously, welding on sufficiently sturdy mounting brackets.

Would standard scaffold poles not be large / thick enough to take the required punishment? Or would they work quite well? Has anyone else tried something similar?

And for those who have tubular HD bumpers... what diameter is the tubing?

They're for a Disco 1, btw...

yes

no

maybe

Are they galvanised ?
if they are you will get poisonous fumes !!! they will splutter and spit.

When makeing a home made bumper the trick is the strength should be in the design . A lot of folk use to heavy gadge steel and over enginer them.end up with something for a tank.

300tdistu said:

Are they galvanised ?
if they are you will get poisonous fumes !!! they will splutter and spit.

Click to expand...

Not poisonous exactly, just grind it off first.....

300tdistu said:

Are they galvanised ?
if they are you will get poisonous fumes !!! they will splutter and spit.

Click to expand...

Bolixx
absolute tosh
Zinc (Galvo) fumes are not toxic at all.
Read the thread in the FAQ section .

They do give of fumes tho (best to weld in open air) and can give flu like symptoms for up to 24 hours if you breath the fumes alot.
Just clean off Galv where yu intend to weld and use a weld thru primer to protect it short term, if you have to.

If you have to weld galvo drink a pint of milk as it does prevent the flu symtoms

Whether poison or not its like none Asbestos brake lineings , You dont want to breath that **** in
:hippie:

mad git said:

Not poisonous exactly, just grind it off first.....

Click to expand...

you cant grind it from the inside

The Mad Hat Man said:

Bolixx
absolute tosh
Zinc (Galvo) fumes are not toxic at all.
Read the thread in the FAQ section .

They do give of fumes tho (best to weld in open air) and can give flu like symptoms for up to 24 hours if you breath the fumes alot.
Just clean off Galv where yu intend to weld and use a weld thru primer to protect it short term, if you have to.

Click to expand...

ok it not going to kill you........ but you will feel ill

why not just pop down to your local steel place and buy the right stuff for the job, scaff tube is not right for a bumper

Make it from steel tubing fit it,check it,be happy then get it galvanized. Not that costly. Place near worcester will gakvanize a bulkhead for £50

So... wear a mask under me welding helmet then?

Gonna have this issue anyhow, as I've bought boot floor sides from YRM... which are Zintek panels... big fan in the back doorway to aid ventilation, methinks...

300tdistu said:

you cant grind it from the inside




ok it not going to kill you........ but you will feel ill

why not just pop down to your local steel place and buy the right stuff for the job, scaff tube is not right for a bumper

Click to expand...

'Cos the scaff tube may be coming my way for 'free'

Dunno then. Research first i guess on safe way.of doing it. Ventilated, canistered mask when you weld?

Grind off galvo where your going to weld, its going to come off anyway when you weld it and if you weld with it on it will spit and not be as good.

my first thought is that it wont be strong enough to take direct impacts, but there's only one way to find out plus its a good learning excercise i've gone through 3 light bars so far, slowly making them better

make a roll cage while you're at it

ive welded lots of galv tube over the years, grind off where yer welding as you would with paint or rust, if youre working outside you shoudnt have any problem with the fumes ... i never have. and have never worn any form of mask for the fumes.