Fabbing a push bar.

Fabbing a push bar.

Postby WoodMotorsports [OP] » September 2nd 2011, 2:53am

I started building my push bar today. I've seen the adapted Avalanche bars used by a few members, but being a two wheel drive I'm going for more of a police style "urban assault vehicle" look, so I decided to roll my own...

First, the upright template:
Image

Then, transfer to some metal. I had some .25"x4" flat stock at the shop, but needed 6"...so I welded two pieces together. That's why that weld line is there:
Image

Now on to the mounting brackets. Made them out of some monster angle iron I had in the scrap pile. Luckily the stock bumper bolts let me line the upright up with the grill separation at the headlights. I did have to heat up the angle and tweak it to line up "square" with the van, because of the curve of the bumper:
Image
Image

Here are the uprights mocked up on the brackets:
Image

That's as far as I got today, which isn't to bad since I was actually working for a living while doing this side project. I did tweak the uprights to match the angle of the line where the grill meets the headlight/turn signals. I've still got to decide what size tubing for the top tube, and will probably use oval or rectangular tubing for the bottom "rung" where you would mount lights.
98 Cargo, making me money daily.
Original Poster [OP]
WoodMotorsports
Fueling (1/8 tank)
Fueling (1/8 tank)
Years of Membership: WoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full years
Posts: 21
Topics: 5
Joined: July 2011
Location: Columbus, GA
Gender: Male
Van Make/Model: Chevrolet Astro
Extra Info: Cargo RWD

Re: Fabbing a push bar.

Postby chevymaherchevymaher is online! » September 2nd 2011, 12:01pm

Very nice a general Lee push bumper.
User avatar
chevymaherchevymaher is online!
Team Leader
Team Leader
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: chevymaher has been a member for 3 full yearschevymaher has been a member for 3 full yearschevymaher has been a member for 3 full years
Posts: 8689
Topics: 58
Images: 93
Joined: November 2010
Gender: Male
Alias (AKA): chevymaher
Year: 1994
Van Make/Model: GMC Safari
Extra Info: SLE RWD cam ported

Re: Fabbing a push bar.

Postby icebrrg3rd » September 2nd 2011, 4:15pm

+1

That's what I'm looking for too, something for the center. Looks great.

-Andrew
81 Yamaha Maxim 650XJ 650cc, 67k mi. Green Beast
83 Yamaha Venture 1300cc, 78k mi. Great White
91 Chevy Astro Conversion 5.7L 5-speed, 243k mi. Rustic Red
00 Dodge Grand Caravan 3.8L, 184k mi. Baby Blue
User avatar
icebrrg3rd
U.S. Armed Forces
U.S. Armed Forces
Firing on 2 Cylinders (L2)
Firing on 2 Cylinders (L2)
Years of Membership: icebrrg3rd has been a member for 4 full yearsicebrrg3rd has been a member for 4 full yearsicebrrg3rd has been a member for 4 full yearsicebrrg3rd has been a member for 4 full years
Posts: 1224
Topics: 38
Joined: October 2009
Location: Milwaukee, WI
Gender: Male
Alias (AKA): Andrew
Year: 1991
Van Make/Model: Chevrolet Astro
Extra Info: RWD Shorty Conv

Re: Fabbing a push bar.

Postby Jasen » September 2nd 2011, 5:01pm

Looking good man. I'd think 3" would look good for the cross bars. 2" seems a bit small and 4" way to big. JMO
I'm a Journeyman woodworker,
Every projects a journey man.

200k
Ultra gauge

Being a mad scientist IS NOT as easy as it look's on TV



Image
Jasen
Site Contributor
Site Contributor
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: Jasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full years
Posts: 7050
Topics: 261
Images: 101
Joined: July 2009
Location: Seattle, Wa
Gender: Male
Year: 1997
Van Make/Model: Chevrolet Astro
Extra Info: AWD cargo Dutch door

Re: Fabbing a push bar.

Postby RECox286 » September 2nd 2011, 9:50pm

If and when I have to push another vehicle, I tie a wheeless tire to the front of the truck, suspended from the hood latch, and that gives me a real good cushy bumper between the pusher and pushee.

Works like a charm, is cheap, and makes me look more "civilian" than "smokey". What I intend on doing is rigging permanent jumper cables under the hood with a battery disconnect switch on the +.

Not against the push bar idea, don't get me wrong, but I have had to jump more times than push. If push came to shove, it might be better to have a tow bar on the front of the truck so you wouldn't need a

tow truck, and usually the cops are only interested in getting a disabled car clear of the road to allow traffic to pass, not long distance hauling/pushing.

Other than that, what you are doing "Looks" very chick. I supose you are going to put a good bit of rubber on the front side ?

Bob
Start a fire for a man and he will be warm for a day.
Set a man on fire and he will be warm the rest of his life.

Sent using two Progresso soup cans and a string
User avatar
RECox286
U.S. Armed Forces
U.S. Armed Forces
Firing on 8 Cylinders (L4)
Firing on 8 Cylinders (L4)
Years of Membership: RECox286 has been a member for 4 full yearsRECox286 has been a member for 4 full yearsRECox286 has been a member for 4 full yearsRECox286 has been a member for 4 full years
Posts: 3810
Topics: 31
Images: 0
Joined: July 2010
Location: South Jersey
Gender: Male
Alias (AKA): Uncle Bob
Year: 1993
Van Make/Model: Chevrolet Astro
Extra Info: RWD V6 [325K mi]

Re: Fabbing a push bar.

Postby WoodMotorsports [OP] » September 2nd 2011, 11:06pm

This is mainly for looks, though I'm happy the bumper bolts worked out to be in the correct spot for my brackets. I do plan to use some 1" or 1.5" flat stock on the front edges of the uprights, and hopefully find some rubber "C" channel trim to clip over that. The Westin bar on my old dually had that, but so far I'm not finding anything online for the rubber trim.

I did chop off a piece of 2" tubing just to get ideas on tubing size, and it's pretty close to what I'm after. I made the uprights close enough to the grill that I'm going to need to contour whatever the top tube ends up being just to clear the point of the hood.

Didn't get a lot accomplished on it today other than painting and permanently mounting the brackets, and drill the mounting holes for the uprights.

Image
98 Cargo, making me money daily.
Original Poster [OP]
WoodMotorsports
Fueling (1/8 tank)
Fueling (1/8 tank)
Years of Membership: WoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full years
Posts: 21
Topics: 5
Joined: July 2011
Location: Columbus, GA
Gender: Male
Van Make/Model: Chevrolet Astro
Extra Info: Cargo RWD

Re: Fabbing a push bar.

Postby Jasen » September 2nd 2011, 11:50pm

Wood try googling loading dock pumpers, semi truck accessories or tow truck supplies,for the rubber bumpers. I think one time searching for the latter I ran across nice thick solid up you can glue on, like you see on tow truck push plates.
I'm a Journeyman woodworker,
Every projects a journey man.

200k
Ultra gauge

Being a mad scientist IS NOT as easy as it look's on TV



Image
Jasen
Site Contributor
Site Contributor
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: Jasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full years
Posts: 7050
Topics: 261
Images: 101
Joined: July 2009
Location: Seattle, Wa
Gender: Male
Year: 1997
Van Make/Model: Chevrolet Astro
Extra Info: AWD cargo Dutch door

Re: Fabbing a push bar.

Postby WoodMotorsports [OP] » September 4th 2011, 12:34am

Jasen, that got me going with the right "google fu", found a couple places that have what I need.

Here is todays pics. Just a couple mocked up top bar shots. Feel free to advise on the look of this. It's 2 1/8" tubing. As you can tell I had to do some cut/fit to get the curve close to where I want it. I'm thinking this one and another similar down just below the top edge of the bumper. Will also do something just above the bumper line as a light bracket point.

Image
Image
Image
98 Cargo, making me money daily.
Original Poster [OP]
WoodMotorsports
Fueling (1/8 tank)
Fueling (1/8 tank)
Years of Membership: WoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full years
Posts: 21
Topics: 5
Joined: July 2011
Location: Columbus, GA
Gender: Male
Van Make/Model: Chevrolet Astro
Extra Info: Cargo RWD

Re: Fabbing a push bar.

Postby Jasen » September 4th 2011, 12:45am

Glad I could point you in the right direction.
I like it. Why not just one tube in front the the bumper and then run some tabs back over the bumper for the lights, or maybe a 1.5" tube running between the tabs set back in over the bumper for the lights.
I'm a Journeyman woodworker,
Every projects a journey man.

200k
Ultra gauge

Being a mad scientist IS NOT as easy as it look's on TV



Image
Jasen
Site Contributor
Site Contributor
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: Jasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full years
Posts: 7050
Topics: 261
Images: 101
Joined: July 2009
Location: Seattle, Wa
Gender: Male
Year: 1997
Van Make/Model: Chevrolet Astro
Extra Info: AWD cargo Dutch door

Re: Fabbing a push bar.

Postby redfury » September 4th 2011, 2:46am

damn, I wish I had metal working skills.
A temporary fix usually becomes a permanent solution, therefore it does not exist.
doghouse removal by me!http://www.youtube.com/watch?v=uIJ0kuROlbU
User avatar
redfury
U.S. Armed Forces
U.S. Armed Forces
Red Status (L3)
Red Status (L3)
Years of Membership: redfury has been a member for 3 full yearsredfury has been a member for 3 full yearsredfury has been a member for 3 full years
Posts: 2096
Topics: 39
Images: 13
Joined: December 2010
Location: isanti, mn
Gender: Male
Alias (AKA): Mike
Year: 1998
Van Make/Model: Chevrolet Astro
Extra Info: LT 5.7L 4wd

Re: Fabbing a push bar.

Postby WoodMotorsports [OP] » September 5th 2011, 9:52pm

Getting close to phase 1 being finished. I'm still planning to weld flat stock to the leading edge of the uprights to attach the rubber C channel, but for now I'm painting and riding as is. The C channel will have to be ordered, and I'm waiting for the company to contact me with prices and options. I really wanted it mounted today, but humidity is to high for my paint to dry quickly, so it's spending the night at the shop tonight.

Image
Image
98 Cargo, making me money daily.
Original Poster [OP]
WoodMotorsports
Fueling (1/8 tank)
Fueling (1/8 tank)
Years of Membership: WoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full years
Posts: 21
Topics: 5
Joined: July 2011
Location: Columbus, GA
Gender: Male
Van Make/Model: Chevrolet Astro
Extra Info: Cargo RWD

Re: Fabbing a push bar.

Postby chevymaherchevymaher is online! » September 5th 2011, 10:38pm

It is looking awsome.My brothers dukes of Hazzard charger jealous now.That is going to look good when your finished.
User avatar
chevymaherchevymaher is online!
Team Leader
Team Leader
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: chevymaher has been a member for 3 full yearschevymaher has been a member for 3 full yearschevymaher has been a member for 3 full years
Posts: 8689
Topics: 58
Images: 93
Joined: November 2010
Gender: Male
Alias (AKA): chevymaher
Year: 1994
Van Make/Model: GMC Safari
Extra Info: SLE RWD cam ported

Re: Fabbing a push bar.

Postby Jasen » September 5th 2011, 11:17pm

Lookin good
I'm a Journeyman woodworker,
Every projects a journey man.

200k
Ultra gauge

Being a mad scientist IS NOT as easy as it look's on TV



Image
Jasen
Site Contributor
Site Contributor
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: Jasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full years
Posts: 7050
Topics: 261
Images: 101
Joined: July 2009
Location: Seattle, Wa
Gender: Male
Year: 1997
Van Make/Model: Chevrolet Astro
Extra Info: AWD cargo Dutch door

Re: Fabbing a push bar.

Postby WoodMotorsports [OP] » September 6th 2011, 2:43pm

Not the nicest day to be taking photos, but I did get it mounted up this morning:
Image
Image
Image
98 Cargo, making me money daily.
Original Poster [OP]
WoodMotorsports
Fueling (1/8 tank)
Fueling (1/8 tank)
Years of Membership: WoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full yearsWoodMotorsports has been a member for 3 full years
Posts: 21
Topics: 5
Joined: July 2011
Location: Columbus, GA
Gender: Male
Van Make/Model: Chevrolet Astro
Extra Info: Cargo RWD

Re: Fabbing a push bar.

Postby Jasen » September 6th 2011, 5:19pm

That'll make those prius drivers get out of your way.
I'm a Journeyman woodworker,
Every projects a journey man.

200k
Ultra gauge

Being a mad scientist IS NOT as easy as it look's on TV



Image
Jasen
Site Contributor
Site Contributor
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: Jasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full years
Posts: 7050
Topics: 261
Images: 101
Joined: July 2009
Location: Seattle, Wa
Gender: Male
Year: 1997
Van Make/Model: Chevrolet Astro
Extra Info: AWD cargo Dutch door

Re: Fabbing a push bar.

Postby redfury » September 6th 2011, 11:00pm

Jasen wrote:That'll make those prius drivers get out of your way.


they won't see the bar though, the alignment of the uprights is almost perfectly inline with the grill lines.
:bow:
A temporary fix usually becomes a permanent solution, therefore it does not exist.
doghouse removal by me!http://www.youtube.com/watch?v=uIJ0kuROlbU
User avatar
redfury
U.S. Armed Forces
U.S. Armed Forces
Red Status (L3)
Red Status (L3)
Years of Membership: redfury has been a member for 3 full yearsredfury has been a member for 3 full yearsredfury has been a member for 3 full years
Posts: 2096
Topics: 39
Images: 13
Joined: December 2010
Location: isanti, mn
Gender: Male
Alias (AKA): Mike
Year: 1998
Van Make/Model: Chevrolet Astro
Extra Info: LT 5.7L 4wd

Re: Fabbing a push bar.

Postby Jasen » September 7th 2011, 1:58am

redfury wrote:
Jasen wrote:That'll make those prius drivers get out of your way.


they won't see the bar though, the alignment of the uprights is almost perfectly inline with the grill lines.
:bow:


The will when it's rubbing up against their head rest :mrgreen:
I'm a Journeyman woodworker,
Every projects a journey man.

200k
Ultra gauge

Being a mad scientist IS NOT as easy as it look's on TV



Image
Jasen
Site Contributor
Site Contributor
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: Jasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full years
Posts: 7050
Topics: 261
Images: 101
Joined: July 2009
Location: Seattle, Wa
Gender: Male
Year: 1997
Van Make/Model: Chevrolet Astro
Extra Info: AWD cargo Dutch door

Re: Fabbing a push bar.

Postby Lumpy » September 7th 2011, 2:21am

Jasen wrote:The will when it's rubbing up against their head rest :mrgreen:


And when you honk those six cadillac Astro Blaster horns behind the grille.





Lump... :layrubber:
Image
User avatar
Lumpy
250k+ Miles
250k+ Miles
Orange Status (L5)
Orange Status (L5)
Years of Membership: Lumpy has been a member for 4 full yearsLumpy has been a member for 4 full yearsLumpy has been a member for 4 full yearsLumpy has been a member for 4 full years
Posts: 4042
Topics: 140
Joined: April 2010
Location: Phoenix AZ USA
Gender: Male
Year: 1989
Van Make/Model: Chevrolet Astro
Extra Info: 9 in. lift Camo

Re: Fabbing a push bar.

Postby Jasen » September 7th 2011, 2:32am

Alright Lumpy, sound off

I'm a Journeyman woodworker,
Every projects a journey man.

200k
Ultra gauge

Being a mad scientist IS NOT as easy as it look's on TV



Image
Jasen
Site Contributor
Site Contributor
Firing on 8 Cylinders (L7)
Firing on 8 Cylinders (L7)
Years of Membership: Jasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full yearsJasen has been a member for 5 full years
Posts: 7050
Topics: 261
Images: 101
Joined: July 2009
Location: Seattle, Wa
Gender: Male
Year: 1997
Van Make/Model: Chevrolet Astro
Extra Info: AWD cargo Dutch door

Re: Fabbing a push bar.

Postby drmmhmd » September 7th 2011, 3:52am

redfury wrote:damn, I wish I had metal working skills.


skills?
drmmhmd
Firing on 1 Cylinder (L1)
Firing on 1 Cylinder (L1)
Years of Membership: drmmhmd has been a member for 3 full yearsdrmmhmd has been a member for 3 full yearsdrmmhmd has been a member for 3 full years
Posts: 157
Joined: July 2011
Gender: Male
Van Make/Model: GMC Safari
Extra Info: AWD 400 CID

Next

 
  • Related topics
    Replies
    Views
    Last post

Return to Exterior

It is currently July 30th 2014, 1:54am

Exterior Forum
ExteriorAnything to do with the outer exterior of your van. Discuss all body modifications and repairs including fenders and bumpers, hoods and grilles, or doors and windows. All body related things like body panels and handles, wipers and roof racks, mirrors and trim.
To create a new topic in Exterior, click this button:
Previous topic Next topic
Recent Image Attachments
Attached by:
Attached by: Duckstar
Duckstar
in Exterior
Views: 317
Comments: 15
Date: Jul 25 '14
Time: 7:43pm
» Read last comment
Attached by:
Lastcat
in Exterior
Views: 187
Comments: 5
Date: Jul 23 '14
Time: 12:20pm
» Read last comment
Attached by:
dhur
in Exterior
Views: 705
Comments: 16
Date: Jun 30 '14
Time: 5:33pm
» Read last comment
Attached by:
dhur
in Exterior
Views: 705
Comments: 16
Date: Jun 30 '14
Time: 4:42pm
» Read last comment
Attached by:
dhur
in Exterior
Views: 705
Comments: 16
Date: Jun 30 '14
Time: 1:49am
» Read last comment
Sponsors
 

Who is online

Users browsing this forum: No registered users and 2 guests