Heavy Duty Rear Truck Bumper Build
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Thread: Heavy Duty Rear Truck Bumper Build

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    flyweight's Avatar
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    Heavy Duty Rear Truck Bumper Build

    My truck(Chevy 2500HD) is equipped with the factory replacement Class III receiver hitch. I bought a new travel trailer(toy hauler) at the end of last Fall and the hitch falls under the unloaded weight of this trailer. I have a Class V receiver hitch, but it doesn't fit the frame rail width of my truck. I was going to build an adapter, but I decided to build a heavy-duty rear bumper and incorporate the Class V hitch into it.

    I had all of the material(steel drop-offs, scrap metal) laying around in my barn that was collected over the years. I also had a Jib(Boom Extension) that was condemned from a 9-Ton crane. This Jib has a "taper" running front-to-back, so this would be just right for the type/apperance rear bumper I wanted to build.
    Click image for larger version. 

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    I cut out the center section of the Jib, then split it down the middle, to form the bumper wings.
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    With a section of 4" heavy gauge channel-iron, I cut to length and drilled these for my bumper mounts.
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    Test fitting the bumper mounts. That hitch in the pic is the Class III that will be discarded.
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    I made a makeshift clamp to hold and bend the 4" x 1/4" flat bar for a drop-down saddle in the middle of the bumper.
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    Bumper saddle.
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    Using makeshift jigs, I assembled the saddle and wings in preparation for welding.
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    I tack welded the assembly and did a test fit on the truck.
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    Once I was satisfied with the test fit, I did a complete weld on the assembly, then wire-brush it and reinstalled it on the truck.
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    All hardware to retain the bumper to the truck is Grade-8.
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    It's not fully complete at this time.

    • The licence plate is temporarily mounted. I ordered a flip-down license plate holder to gain access the spare tire crank.
    • The 7-way/4-way trailer plug is also temp mounted at this time. I plan to install it to the left of the license plate within the saddle.
    • Bumper end caps will need to be made and welded into place.
    • I'll also need to figure where I'll install the trailer safety-chains attaching points.


    Once all the above is done, I'll remove the bumper for sand blasting, priming and painting. Then, the final installation will be done.

    In a couple months, I'll begin building a HD front bumper.
    In fact, for that project I ordered weldable 3/4" clevis mount from Ken last week. Thanks, Ken..........
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    -------------------------------------------------------------------------------------------------------------------------------



    While I had the new bumper installed, I decided to take the boat out for a ride.
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    Yep. It still floats.
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    Last edited by flyweight; 03-03-2018 at 09:47 PM.
    Michael

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    etcallhome's Avatar
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    Nice ,,,very nice

    Just wondering do you think it is heavy enough. pity the poor soul that would ever rear-end you.
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    Gene

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    Doug's Avatar
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    Are you sure your hitch is only a class 3. I would think a HD 2500 would have at least a class 4 or even class 5.

    Doug

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    I like it! what color are you painting it JD Green?
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    Sometimes when I read a thread, I hope that it's an old one that has been updated and I can see the finished product. Now I gotta bookmark and wait in "real time".

    Looks great so far, very nice work!

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    flyweight (03-04-2018)

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    flyweight's Avatar
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    Quote Originally Posted by etcallhome View Post
    Nice ,,,very nice. Just wondering do you think it is heavy enough. pity the poor soul that would ever rear-end you.
    Gene, the wings are 5/32", saddle is 1/4", saddle backing plate is 1/4", all bracing is 1/4".
    I'm going to weigh it when I have it off for blasting/painting. Until then, my guess is it's close to 150 Lbs.

    Quote Originally Posted by Robnik View Post
    I like it!what color are you painting it JD Green?
    Gizmo Black.
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    Michael

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    Also have a bunch of other stuff.
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    - John Wells - Brewster County, West Texas.










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    flyweight's Avatar
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    Quote Originally Posted by Doug View Post
    Are you sure your hitch is only a class 3. I would think a HD 2500 would have at least a class 4 or even class 5.
    Sorry, Doug. I should have stated Factory Replacement Class III. You're right, this truck should have come equipped with a Class IV, or V.
    Truck trailering info: 2500 CC SWB 4WD 6.6L TD 12,000/14,200

    For some reason, the OEM hitch was replaced. I'm the second owner. The original owner traded the truck for a newer year model and I bought it from the dealer. What happened to the original OEM hitch is a mystery. The truck is equipped with a trailer towing package. Maybe someone needed/wanted the OEM hitch.

    Below is the hitch that was on the truck when I bought it.
    Click image for larger version. 

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    Last edited by flyweight; 03-03-2018 at 10:31 PM.
    mjncad, Gizmo2, DRobinson and 11 others like this.
    Michael

    2019 JD Z540R 54" cutting deck w/MulchControl™
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    Also have a bunch of other stuff.
    ---------------------------------------
    " If there's no one around to smell me, do I really stink"?
    - John Wells - Brewster County, West Texas.










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    I don't see where you stated the year of your pickup. I believe many of the older 3/4 ton pickups had the class III hitches with a 10,000# max. As best I remember, my 97 F250 had a max of 10,000#. My 2011 F250 has the Class IV with a 12,000# max, but it also has a 9800# GVW, whereas the 97 had a GVW of just over the 8500# threshold.

    On the other hand, I don't believe Hidden Hitch was an OEM option. Also, many of the older 3/4 ton pickups did not have a frame hitch at all and had to be added on. Pretty much all of them have the hitch today, even 1/2 tons.

    Dave
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    Big
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    Looks good. You gonna weld end caps on the ends of the bumper? Would hate to walk around the back of your truck and catch a knee cap on the exposed channel.....Just a thought. Looks like it's going well and would like to see finished product pics!

    Never mind the end cap question. I should have read completely. My bad. Looks like you got it all under control.
    Last edited by Big; 03-04-2018 at 12:33 AM. Reason: Didn't read previous post
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    Now you need to do what an acquaintance at my last job did to his 80's vintage Suburban. He got tired of the cheap pre stainless steel exhaust systems rusting out that he replaced it with 2" SCH40 or SCH80 pipe. I kid you not. It lowered the center of gravity as a bonus.
    rtgt, Levi, OxPath and 6 others like this.
    I have more ideas than ambition.


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