Well, I got access to the shop at work now so I figured I'd have a little fun and build my self a new rear bumper..
****Note: Dimensions are to be confirmed*******
The plan would be trim the rear fenders horizontally to clear the wrap-around C-channel, and mitre the ends of the C-channel to follow the curve of the wheel well down (will also trim back fenders in the process).
Then bolt the C4x5.4 channel to the existing bumper mounting holes and drill 4 holes thru the frame and the plates to mount the transverse braces to the frame...
I will be making a jig to represent the frame while welding this to keep it from bending and distorting...
Any suggestions??? Should I make it almost flush with the tailgate, or extended out with a piece of plate on top like a normal bumper????
Should I extend the C4x5.4 channel out so I can bolt the transverse braces thru that too????
Is 138lbs too much?? Any idea how much a stock bumper weighs? 60lbs??
Sorry for all the questions, any constructive criticism will be much appreciated.