MOVE Bumper DIY Bumper Kit

Part 2: Weld-It Yourself

In the June issue of Diesel World, we introduced the first part of this bumper project. Move Bumpers of Lewiston, MT, engineers and designs pre-cut and pre-formed pieces to allow you the end user the pieces needed to fabricate a perfectly fitting off-road bumper for your specific truck. The Move Bumper DIY kits are not only less expensive than other options on the market, but they can save a fortune on freight and shipping costs since the plate steel pieces can be shipped inside a standard box via FedEx/UPS right to your front door. For the guy with some fabrication skills and the proper tools, like a MIG welder, grinder, cutoff tool, etc., these bumper kits can be pieced together in just a few hours and hug the factory body lines almost perfectly. There is a sense of pride that comes from building something with your own two hands, especially if you can take your time, producing a fine looking final piece to hang off the front of your truck.

Recap

In part one, the bumper pieces were all tack welded together using the truck itself as the jig. The frame mounts were bolted on, followed by the center piece which was lined up to follow along flush with the bottom of the grille. Once it was tacked in place on the frame brackets, the outer wings could be positioned and tacked onto the center. The end caps to the bumper were then tacked to the outer wings, and the bumper could then be removed from the truck for final welding to be completed.

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Finish Work

For this bumper, it was decided to weld both the front and back side of each seam. This filled any holes and valleys where water could collect and start corrosion points within the bumper; it also helped make it the strongest it could be. Once all the welding was completed, the bumper was test fit back on the truck to make sure nothing moved or tweaked out of place from warpage. Knowing it all fit like it should, the bumper came back off and about an hour was spent grinding and sanding down all the welds along the outer edges. Smoothing them down with the grinder first and following up with a fine grit sandpaper on an angle grinder made the pieces all become one. After getting cleaned up it was dropped off at the local powder coat shop who promptly sand blasted it and covered it in a zinc based etching primer which would help the bare steel fight against rust and corrosion. After proper drying time, the bumper went into the spray booth to get a thick coat of textured black powder coat that was baked on for proper adhesion and strength. The color turned out perfectly and looks great on the all-black Chevy truck it was built for. While the owner opted for the powdercoat, these bumpers could also be painted to match any truck or even coated in a rubberized spray-on bedliner material.

Using a Millermatic 210 Miller mig welder, every seam on the bumper was melted together with a clean bead, on both the front and backsides.

A flap disc on the angle grinder made short work of the welds and smoothed things out to near perfect smooth transitions. Some of the welds revealed low spots or holes that were filled and ground again making for perfect rounded edges.

Let There Be Light

For lighting the way, a couple sets of LED lighting kits were ordered up from Tigerlights.com, which included two sets of their square floodlights and their 20-inch Crossfire LED Light Bar. Using all stainless steel hardware and patented dual row side emitting led bulbs, they offer a cleaner more efficient light output than many others on the market. The all-aluminum housings are both dust and waterproof to ensure years of trouble-free performance, regardless of conditions; and they look great too.

To fill the pre-cut holes in the Move Bumper, two sets of square fogs and a 20-inch LED bar were purchased from TigerLights.com, who works closely with Move Bumper, so you know they’ll all fit and bolt together like they should within the bumper.

The outer fog light kits were mounted up inside the pre-cut holes on the outer wings of the bumpers. It was decided that the outer most set of lights would be angled out to broaden the field of light to show the sides of the highway since the inner fogs and 20-inch light bar would be used to brighten up what was exactly in front of the truck on the road. Tiger Lights also suppled professional wiring harnesses with waterproof connectors, loomed wires, relays and quality toggle switches.

Switched on

While the supplied toggle switches would have worked fine, the truck owner didn’t want to add more holes and switches to his dash board, so Edge Products was called upon to supply their latest EAS Switch kits, which can be used with the expandable daisy chain-style Edge Accessory System that works in conjunction with the CTS2 Insight monitor the truck was already running. The Edge CTS2 Insight was already being used as an in-cab monitor for watching fluid temperatures, EGT’s and a back-up camera, so why not use it to turn on some 12-volt accessories, as well? With the new EAS Switch kits, the new lighting could be wired into some under-hood pigtails that would daisy chain into the EAS kit already on the truck and allow the lights to be powered on/off via the in-cab touchscreen. This meant no more wires had to be routed through the firewall, and no more switches had to be mounted to the dash. Everything is controlled via the CTS2 screen.

The center light bar mounts off the ends with two Allen head bolts. This allowed the light to be positioned in the vertical center of the opening, but we were also able to adjust how far forward it sat in the bumper. It was opted to have the light bar set back, so it was flush with the topside of the opening and protected by the bumpers outer shell.

– Instead of using the supplied switches in the Tiger Lights harness, for this install, a set of the new EAS Switches from Edge Products were used. This system daisy chains into the EAS system already installed on the truck that work in conjunction with the Edge CTS2 Insight monitor, so the touch screen will be used to turn our lighting on/off.

With the Edge Products CTS2 Insight, once all the wiring is completed on the lights, the ‘Switch’ screen can be setup and labeled to display up to four switches. Three of these will be used to power up our Tiger Light kits.

Satisfaction

MOVE Bumper has created a unique product that can fill a large void within our market, offering an inexpensive product for the DIY truck owner not afraid to get his hands dirty and do a little fabrication on his own. When outfitted with a couple LED Tiger Lights and the Edge EAS Switch system, it all works out to be a great addition for any truck, whether it’s used strictly off-road or running down the highway on a dark backcountry night. These heavy duty bumpers are inexpensive, effective, good looking and they even add some additional functionality to your truck: a homerun on every count. DW

Welding Tips:

When it comes time to lay the final beads on all the seams, remember to take your time and bounce around from one spot to another. Too much heat in one place can cause the pieces to start to warp and knock the bumpers alignment off when it goes back on the truck.

SOURCE:
Move Bumpers
MOVEBumpers.com
877.462.4816

Tiger Lights
TigerLights.com
877.928.1646

Edge Products
EdgeProducts.com
888.360.3343

FREQUENTLY ASKED QUESTIONS

How did Thomas Smalley and Josh Hunt complete the bumper assembly process?

Thomas Smalley and Josh Hunt undertook an impressive bumper assembly journey, demonstrating resourcefulness and skill. They began by working tirelessly in a garage, where they meticulously assembled, welded, and sanded the components of a heavy-duty truck bumper. Their teamwork allowed them to complete this initial phase in just half a day.

Once the raw assembly was finished, they transported their project to Double R Powder Coating & Fabrication, located in Sutherlin. Here, the bumper received a professional finish with a textured, semi-gloss black coat, enhancing both its durability and aesthetic appeal.

With the freshly coated bumper in hand, they returned to their workspace to complete the installation. This involved integrating TigerLight LEDs, which were added to boost the truck’s lighting capabilities, before finally mounting the bumper onto the truck. This methodical process highlighted their commitment to executing quality upgrades even while working within a budget.

What finishing processes were used to complete Thomas Smalley’s bumper?

To complete Thomas Smalley’s bumper, several finishing processes were meticulously followed. Initially, the assembled bumper underwent welding and sanding to ensure a smooth and sturdy structure. It was then sent to a professional facility for a powder coating treatment, featuring a textured, semi-gloss black finish. This coating not only enhanced the appearance but also provided additional durability and protection against the elements. Finally, after returning to the workshop, LED lights were installed, and the bumper was securely mounted onto the vehicle, ready for use.

How important is the positioning of L-brackets in the bumper assembly process?

The Importance of L-Bracket Positioning in Bumper Assembly

In the intricate process of assembling a bumper, the positioning of L-brackets is a cornerstone for achieving both structural integrity and aesthetic alignment. Proper alignment of these brackets is not just a technicality—it’s essential for ensuring your bumper fits perfectly and functions as intended.

Ensuring Structural Stability

Alignment with Angles: Position the L-brackets carefully, aligning the angled edge of the bracket’s short leg with the bumper’s angled bottom. This alignment is crucial for maintaining the overall structural stability of the assembly.
Utilizing Welding Magnets: Tools such as welding magnets are invaluable. They assist in holding the brackets and gussets in place, allowing for precision in maintaining square alignment during the welding process.

Facilitating Future Adjustments

Adjustable Placement: Before affixing the brackets permanently, ensure the end-plate bolts are centered in their slots. This configuration allows for future adjustments, enabling you to shift the bumper left or right, fine-tuning the fit for desired outcomes.

Precision in Initial Steps

Tack Welding Strategy: Initially, employ tack welds to secure the L-brackets. This approach provides the flexibility needed to adjust the opposite side, ensuring all components are perfectly aligned before committing to permanent welds.

Failing to position L-brackets accurately can lead to misalignment, reducing the effectiveness of the bumper and potentially causing complications down the line. By prioritizing careful positioning, you not only facilitate an easier installation process but also extend the functional life of the bumper.

How did Thomas Smalley manage to build a custom bumper on a college-student budget?

Thomas Smalley, a resourceful college student strapped for cash, cleverly built a custom bumper without breaking his budget. By leveraging his developing welding skills, he discovered a cost-effective DIY kit that offered all the necessary materials and instructions. This approach allowed him to craft a personalized bumper without paying for expensive professional services. Embracing this hands-on solution not only saved him money but also gave him a rewarding learning experience.

What motivated Thomas Smalley to build his own custom heavy-duty bumper for his Ford F-250?

Thomas Smalley was driven by his passion for enhancing his ’99 Ford F-250 with a unique heavy-duty front bumper. Despite his eagerness, the high cost of purchasing even a budget-friendly one put a strain on his tight college finances. This financial hurdle motivated him to take matters into his own hands. Determined to achieve his vision without overspending, Thomas decided to build a custom bumper himself, combining creativity and resourcefulness to create a solution that suited both his style and budget.

What benefits does the MOVE Bumper provide for a Ford F-250?

If you’re considering upgrading your Ford F-250, the MOVE bumper offers several compelling benefits:

Enhanced Front-End Protection: The MOVE bumper significantly boosts the resilience of the truck’s front end. This reinforced barrier is designed to withstand impacts, safeguarding vital components of your vehicle.
Superior Lighting Options: Equipped with exceptional auxiliary lighting capabilities, the MOVE bumperimproves nighttime and low-visibility driving conditions, ensuring safety on and off-road.
Durable Construction: Crafted from high-quality materials, this bumper promises longevity and resistance to harsh elements and challenging terrains.
Customizable Design: It provides options for tailoring the appearance and functionality to match your specific needs and style preferences without compromising on performance.

By integrating a MOVE bumper, F-250 owners can enjoy robust protection and enhanced functionality, transforming their driving experience into a safer and more efficient journey.

What are the features of the mid-priced Prerunner MOVE Bumper version?

Features of the Mid-Priced Prerunner Bumper Kit

The mid-priced Prerunner bumper kit comes packed with several attractive features:

Customizable Lightbar Cutout: It includes an optional 30-inch lightbar cutout, providing flexibility for those looking to integrate additional lighting, which enhances visibility during nighttime or off-road driving. This feature is an add-on at a cost of $50.
Structural Tubes: The kit is equipped with three robust 2 1/2-inch tubes. These tubes add extra protection and a rugged look, making your vehicle not only more durable during off-road adventures but also more stylish. This feature is available for an additional $75.
Affordable Pricing: Priced at a total of $620, this kit offers a budget-friendly alternative compared to similar pre-finished bumpers, which can easily reach costs of nearly $2,000, making it an economical choice for those wanting style and protection without breaking the bank.

Overall, this package strikes a balance between cost-effectiveness and functionality, providing substantial savings while delivering on essential features for off-road enthusiasts.

What are the different styles and price points of MOVE Bumpers’ DIY kits?

When exploring the different styles and prices of MOVE Bumpers’ DIY kits, you’ll find three primary options to consider.

Standard Kit: Priced at $395, this option offers a solid foundation for customizing your vehicle’s front end.
Pre-Runner Kit: For $495, this style provides additional features, making it a popular choice for those looking for more than the basics.
Full-Grill Kit: At the top of the range, the Full-Grill style costs $750, offering maximum coverage and customization potential.

Each kit includes cutouts designed for two pairs of square light holes on the sides and a 20-inch light bar at the front. If your needs require a 30-inch light bar or just a single set of square lights, you can add these for an extra $50. Additionally, a winch mount setup is available for $75, although this does require modifications to the bumper face for the fairlead.

How does the DIY MOVE Bumper compare in cost to pre-finished bumpers?

For a more detailed cost comparison, consider the mid-priced Prerunner version of the MOVE Bumper kit, complete with the optional 30-inch lightbar cutout ($50) and three 2 1/2-inch tubes ($75). The total cost comes to $620. In contrast, pre-finished bumpers of similar quality usually price in at nearly $2,000. This makes the DIY option not only budget-friendly but also a smart choice for those looking to invest in quality without breaking the bank.

How does the cost of the DIY kit compare to pre-finished bumpers?

The DIY kit offers significant savings, as similar quality pre-finished bumpers typically cost nearly $2,000.

What is the exact cost of the DIY MOVE Bumper kit?

The DIY MOVE Bumper kit, specifically the mid-priced Prerunner version with additional features, costs $620.

What tools are helpful during the MOVE Bumper assembly process?

In the June issue of Diesel World, we introduced the first part of this bumper project. Move Bumpers of Lewiston, MT, engineers and designs pre-cut and pre-formed pieces to allow you, the end user, the pieces needed to fabricate a perfectly fitting off-road bumper for your specific truck. The Move Bumper DIY kits are not only less expensive than other options on the market, but they can save a fortune on freight and shipping costs since the plate steel pieces can be shipped inside a standard box via FedEx/UPS right to your front door. For the guy with some fabrication skills and the proper tools, like a MIG welder, grinder, cutoff tool, etc., these bumper kits can be pieced together in just a few hours and hug the factory body lines almost perfectly.

Building your own MOVE Bumper isn’t just about having the right kit—it’s about using the right tools effectively. Here are some indispensable tools that will make your assembly smooth and efficient:

Tack Welder: This is essential for the initial welds, especially when attaching the passenger’s side L-bracket to the center section. It’s a critical step that sets the foundation for the entire build.
Welding Magnets: These are a game-changer, ensuring square placement of brackets and gussets. They help maintain the precision needed for a sturdy assembly.
Angle Grinder with a 4 1/2-inch Flap Disc: This is the second most used tool in the process. It’s perfect for smoothing out the bumper edges, giving your build a professional finish.

Teamwork can also accelerate the process. While one person continues welding, another can use the angle grinder to smooth welds and edges, proving that collaboration truly speeds up the MOVE Bumper kit build.

With the right tools and a bit of sweat equity, your custom bumper will not only be functional but also a testament to your craftsmanship.

How does teamwork play a role in the assembly process?

Teamwork enhances efficiency, with one person focusing on welding while another grinds the welds and edges smooth.

What tool is particularly useful for smoothing edges?

An angle grinder equipped with a 4 1/2-inch flap disc is ideal for smoothing the edges of the bumper.

What tools help ensure precise placement during assembly?

Welding magnets are instrumental in ensuring the square placement of brackets and gussets during the assembly process.

How should the L-brackets be positioned?

The L-brackets should be positioned with the angled-edge of the bracket’s short leg aligned against the angled bottom of the center section.

What is the first step in the assembly process?

The initial step involves tack welding the passenger’s side L-bracket to the MOVE center section, which is crucial for establishing the foundation of the entire build.

What materials and technology does MOVE Bumpers use to produce their bumper kits?

To ensure precision and quality, MOVE utilizes advanced 3D design technologies, combined with state-of-the-art CNC machines and metal-forming equipment. Each piece of the kit is crafted from robust 3/16-inch plate steel, ensuring durability and strength. This meticulous process allows MOVE to deliver a product that maintains high standards while empowering customers to complete the final assembly and finish work themselves.

By choosing MOVE, you’re not just purchasing a bumper kit; you’re investing in an experience that combines cutting-edge technology with the satisfaction of personal craftsmanship.

What part of the process is completed by MOVE and what is left to the customer?

MOVE Bumpers handles the production of all kit components, which are then shipped to the customer. The customer is responsible for the final assembly and finish work.

What material is used for the bumper kits?

The kits are made from durable 3/16-inch plate steel, ensuring strength and resilience.

What specific technologies are used in production?

MOVE Bumpers utilizes advanced technologies such as 3D design software, CNC machining, and metal-forming equipment to craft the components for their kits.

What is MOVE Bumpers’ approach to creating customizable bumper kits?

To achieve this level of customization, MOVE uses cutting-edge 3D design technologies, CNC machines, and metal-forming equipment, ensuring each component is crafted with precision from 3/16-inch plate steel. This meticulous approach allows them to produce all the necessary pieces to match each customer’s specifications.

The Move Bumper DIY kits are not only less expensive than other options on the market, but they can save a fortune on freight and shipping costs since the plate steel pieces can be shipped inside a standard box via FedEx/UPS right to your front door.

For those with some fabrication skills and the proper tools—like a MIG welder, grinder, and cutoff tool—these bumper kits can be assembled in just a few hours. The pieces are designed to hug the factory body lines almost perfectly.

There is a sense of pride that comes from building something with your own two hands, especially if you can take your time, producing a fine-looking final piece to hang off the front of your truck.

By leaving the final assembly and finish work to customers, MOVE empowers DIY enthusiasts to create a personalized touch for their vehicles. This combination of advanced manufacturing techniques and customer involvement not only delivers a high-quality product but also a rewarding experience.

Who is responsible for the final assembly and finishing of the bumper kit?

Customers are tasked with the final assembly and finishing touches, allowing for a personalized build experience.

What material is used for the bumper kits?

The kits are constructed from 3/16-inch plate steel, ensuring durability and strength.

What technologies are used in the creation of the bumper kits?

MOVE Bumpers utilizes advanced technologies including 3D design, CNC machining, and metal-forming equipment to craft their kits.