22 Nov The Project X Story: Chapter IV, Bump It Up!
Now we’ve gone straight from the easiest part of the fabrication to the hardest. Enjoy today’s chapter of the Project X Story.
The front bumper was something we were looking forward to making for a while. We had designed the entire front end on our computers, and the mock-up looked good, so we went about the fun task of constructing this system with nothing but the tools available to us and all the mild steel in the shop.
Using a small bender, we had to triple-check every angle to ensure we were bending correctly. Thankfully, we got everything right on the first try.
We also had to make the mounts from scratch, carefully checking the angles to make sure they’d fit snugly around the main bumper bars.
With the front mounts created, we added the main bars to the front mounts to see how everything was fitting together at that time. Again, our triple-checking paid off, and fitment was spot on.
After a quick test-fit, it was time to begin assembly. Tack welds began forming, followed by full-on TIG welds. At that time, we also finished our radiator cover, which consisted of several rows of dimple-cut steel. That way, it didn’t block airflow to anything vital, and it maintained that aggressive look we were searching for.
Once the welds were completed, we threw ‘er back on the X5 to see how it looked. In a word? Stunning.
Once the front bumper was ready for powdercoating, we set it aside and started on the last of the Big Three – the roof rack! We’ll cover that next time in The Project X Story.
Yaroslav
Posted at 09:20h, 19 MarchHi FMU.
Very impressive design. it’s just perfect.
What is the specification of bars, which are used for front bumper?
Are they really strong enought?
What is the total weight of all front construction?
thank you.
fluidmotorunion
Posted at 12:36h, 19 MarchThanks for the kind words. Our front bumper was created from hand-bent 2″ mild steel bars, and the dimple panel was made from mild steel blanks as well. They’re incredibly strong, and are bolted to the frame of the car for extra rigidity. We’re not sure of the total weight, but it’s a couple hundred pounds (100-150 kilos).
Etienne Darby
Posted at 02:11h, 15 SeptemberHi there! Love your work.
Could you tell me what software did you use to draw the front bumper? Id like to sketch one out for my 325ix wagon!
fluidmotorunion
Posted at 14:45h, 25 SeptemberAutocad!
Trey Burcham
Posted at 20:30h, 06 MarchI like the bumper not to much on the price but would you be able to design a winch mount for this bumper or a similar prerunner/winch bumper I know the have been designed for Toyota but not much for X5 E53’s. Also have yall designed the x5 lift kit for non airbag suspension models yet? It’s been about a yr since I contacted yall last time.
fluidmotorunion
Posted at 10:05h, 22 MarchWe have not – but are working on getting new lift kits for the X5 as we speak!