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Old 09-20-2021, 05:11 PM   #41
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Brand: Thor Motor Coach
Model: ACE 30.2
State: Illinois
Posts: 41
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interesting solution to the bumper problem on your model.
I wish the RV MFG's would just put one were it belongs from the factory. But anything to save a penny.
Thanks,
Scott

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Old 09-20-2021, 05:16 PM   #42
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previous project to this one - rear trackbar

The project I completed just before starting this one was a rear trackbar.
I had read were people were using top links and I thought that was a great idea - I bought the one with a 1" eyehole. Here a few pics shot by my son who was helping me.
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Old 09-21-2021, 01:46 AM   #43
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Originally Posted by sdsstep545 View Post
I had to look up your RV. That is a really nice RV.
A bull bar would definitely be helpful to reach the widshield.
Thanks. I have been pleased with it.
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Old 09-27-2021, 02:19 PM   #44
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Bumper extension tack welded

Now need to complete all welds, grind down as smooth as I can get it and paint bumper. I also received frame rail pieces from old pickup truck from friend to start configuring frame ext to sandwich plates.
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Old 09-27-2021, 02:29 PM   #45
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Old 09-27-2021, 03:10 PM   #46
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Thank you for the support.
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Old 09-27-2021, 07:13 PM   #47
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You did a great job laying out this project, very neat and professional. Turned out fantastic. Just one comment I hope you won't take wrong. You need to crank the heat up on your weldor. It's pretty cold and not getting super penetration. I've been a certified welder in the past and welding for 50 years, so this is an observation that I saw with the mounts. Thanks for your idea and it will give you that extra protection if you ever bump into someone.
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Old 09-27-2021, 08:17 PM   #48
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Originally Posted by Mulerider View Post
You did a great job laying out this project, very neat and professional. Turned out fantastic. Just one comment I hope you won't take wrong. You need to crank the heat up on your weldor. It's pretty cold and not getting super penetration. I've been a certified welder in the past and welding for 50 years, so this is an observation that I saw with the mounts. Thanks for your idea and it will give you that extra protection if you ever bump into someone.
Comment well received.
10-4 on the heat issue. I have a lincoln 180 welder and it definitely is not throwing the heat. I am going to probably have to drag the stick welder back out to get the heat I need. My rods are so old, I am going to have to put them in the oven to bake the moisture out again. My wife will love that!
I am self taught welding. Sometimes I get really pretty welds and some look like garbage. It also did not help that I was welding in the driveway with lots of wind blowing my gas away and on 40' of extension cord.
Thanks,
Scott
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Old 09-27-2021, 08:47 PM   #49
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You did some awesome fabrication on the bumper. Canít wait to see the pictures of finished product.
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Old 09-27-2021, 08:50 PM   #50
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You did some awesome fabrication on the bumper. Can’t wait to see the pictures of finished product.
thanks, I have to fix the poor tack welds, but I should be able to do that on a still day and get it off the rv, laying flat. Then the grinding begins.
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Old 09-27-2021, 09:16 PM   #51
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Originally Posted by sdsstep545 View Post
Comment well received.
10-4 on the heat issue. I have a lincoln 180 welder and it definitely is not throwing the heat. I am going to probably have to drag the stick welder back out to get the heat I need. My rods are so old, I am going to have to put them in the oven to bake the moisture out again. My wife will love that!
I am self taught welding. Sometimes I get really pretty welds and some look like garbage. It also did not help that I was welding in the driveway with lots of wind blowing my gas away and on 40' of extension cord.
Thanks,
Scott
Not only would I have to bake my rods but sand the rust off the bare end before I put them in my Lincoln 225 AC welder. I'm self taught as well and got much better when I discovered self-darkening glass in welding helmets. That's not to say I'm good; just better than I was.
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Old 10-05-2021, 03:06 PM   #52
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bumper painted/ frame rail being cleaned up

I finished welding the bumper and grinding it back down. I painted it hammered black and now you can see every grind line and imperfection. But in general it seems to look pretty good. I have started cleaning up the frame rails from my friends old truck. I am definitely going to have to roll out the old buzz box to get these welds to work - very heavy gauge steel.
-Scott
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Old 10-05-2021, 03:40 PM   #53
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Yes, the 40ft extension cord did take away your heat and the wind really messes the weld up. With the Lincoln 225 weldor use 7018 rod if you have some. Drying it in the oven would be great. Slip it in when you're wife is baking a pie. �� (Not) We live in Arizona so it gets baked quite often. I have a wire feed also and with 1/4 inch metal I will take my torch and heat up the metal then weld it. Get lot better penetration. Thanks for your reply and good luck. You can buy the hammered paint, really covers up imperfections and it's tough.
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Old 10-05-2021, 03:51 PM   #54
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Originally Posted by Mulerider View Post
Yes, the 40ft extension cord did take away your heat and the wind really messes the weld up. With the Lincoln 225 weldor use 7018 rod if you have some. Drying it in the oven would be great. Slip it in when you're wife is baking a pie. �� (Not) We live in Arizona so it gets baked quite often. I have a wire feed also and with 1/4 inch metal I will take my torch and heat up the metal then weld it. Get lot better penetration. Thanks for your reply and good luck. You can buy the hammered paint, really covers up imperfections and it's tough.
10-4 on the rods. I just bought some from Amazon. My rods are over 40 years old, and I dont want to play with old stuff right now. I dont have the time to screw around with it. I have two weeks to finish this build before we head out for our last campout of the year. We are going to camp at state park along the illinois river with 4 other families from our church. Should be a nice weekend. Hopefully it does not rain.
Thanks for the welding rod info.
-Scott
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Old 10-13-2021, 06:42 PM   #55
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Frame Mount Plates

We made two frame mount plates out of 3/8 hot rolled plate steel.
The bolts are 12mm flange bolts. Passenger side is temped in with random bolts.
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Old 10-13-2021, 06:55 PM   #56
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Building frame to bumper chassis extensions

I cut up the truck frame to make expandable chassis extensions.
One side will be welded to the chassis plate and one side welded to the inside bumper sandwich plate. When they are welded and bolted back in place, bolts will be placed thru the two slides to lock them together. This will make for easy install and removal if needed.

The Wooden template was used to get the alignment of the plates to each other and then transfer to the truck chassis rail to make proper cuts. I finished the passenger side extension yesterday and started the drivers side today. They are mirrors of each other. They will be left open from the inside to place bolts into brackets and install bolts thru slides to lock them in place.

I am uploading this now, instead of working because it is RAINING again!
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Old 10-13-2021, 06:57 PM   #57
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pictures of template and expandable extensions

pictures of template and rails
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Old 10-18-2021, 01:30 PM   #58
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Its done.

The mounts are in and the bumper on. We are headed out for camping at Illini state park along the illinois river. We get to watch the tug boats push barges up and down the river.
-Scott
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Old 10-18-2021, 01:32 PM   #59
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Originally Posted by sdsstep545 View Post
The mounts are in and the bumper on. We are headed out for camping at Illini state park along the illinois river. We get to watch the tug boats push barges up and down the river.
-Scott
That's one beautiful piece of art!
Thanks for sharing your project
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Old 10-18-2021, 01:37 PM   #60
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1st campout after bumper added

Illini State park - was like a swamp from all the rain.
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