Date: Thu, 30 Sep 2004 15:58:14 -0700
Reply-To: Doug in Calif <vanagon@ASTOUND.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Doug in Calif <vanagon@ASTOUND.NET>
Subject: Re: Home Made Bull Bars--Pipe Benders
Content-Type: text/plain; charset="iso-8859-1"
I have to chime in here.
I was initially impressed with the aftermarket tube bumpers and especially
the diamond plate step on top, as I am constantly gently stepping up on the
bumpers of my vanagons for one reason or another and wish they provided a
designed step.
The weight of the aftermarket bumpers is an absolute deal breaker for me
adding 150lbs of steel to the ends of the vanagon to me is just plain nuts.
Reminds my of my youth when I was into 4x4 domestic stuff and the more steel
you could get on your truck the better.
I think many folks overload the vanagon based upon its huge cargo area and
its GVWR spec. 150lbs of payload is much more valuable to me.
Why build a bumper out of tubing at all? use channel or square tube and
cover it in either aluminum plate or steel plate.
You are going to powder coat it or paint it black anyway.
You could make a bumper very similar a cross between a modern tow truck or
big rig and the late model fiberglass bumper and it would have a top step
and be much stronger.
Wench mount in the center and set up with lights or whatever.
Heck with the tubing, fab it out of steel. Keep the weight down.
As long as you are stronger than stock and can stand on it you are doing
better,
You wont have to use 75lbs of steel if you build it right.
Ever notice how much light materials are being used on big rigs these days?
the whole front bumper is alloy.
Doug
----- Original Message -----
From: "Gary Lee, Vanagon Racks" <gary2a@TELUS.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Thursday, September 30, 2004 3:22 PM
Subject: Re: Home Made Bull Bars--Pipe Benders
> > I want to construct a front bull bar bumper that looks
> > much like the "Projectzwo"-spelling? bumper that was
> > discontinued....Does anyone know if this pipe bender
> > would
>
> I don't often post on the lists, but here is something I know a little
> about.
>
> Pipe and tube are two different things. Pipe is measured by the ID, is
used
> to transport gas and fluids, has a rough outside finish, is typically much
> heavier than tube and has a thicker wall.
> Tube is measured by the OD, is used in structural applications, has a
smooth
> finish and costs more than pipe.
> Tubing is what you use to build things, like tube frame race cars and
> furniture. The projektzwo bumpers are made of tubing.
> Bending pipe is much easier than tube because of the thicker wall.
Bending
> tube is not something you can do (even badly) without significant
equipment.
>
> Bending EMT and conduit is relatively easy, but those materials are not
> suitable for structural applications. The bend radius is also to big.
>
> Muffler shop benders are compression benders, unless the shop has a
mandrel
> bender. Compression benders produce wrinkles on the inside of the bend,
> most people would find this unacceptable for appearance reasons. Also,
> muffler tubing is not strong enough to be used for bumpers.
>
> Personally, I don't think anyone could produce for sale acceptable bumpers
> made out of pipe. I only say this to give you an idea of what the
finished
> bumper will look like, it will look home made. The rough finish of pipe
has
> a crude appearance, the wide radius bends don't look correct and the
weight
> would be very high. However, as a home DIY project I say go for it. You
> can also use weld elbows and piece the whole thing together, no bending
> required.
> It will take hours to grind the joints smooth though. Also, all the bends
> will be either 90 or 45 degrees. This does not look correct.
>
> Tube bumpers (and other items made of tube) may seem expensive, but the
> equipment required to make them costs a lot of money.
>
> In answer to your original question about the suitability of the Harbor
> freight bender, the short answer is - no it will not do what you want.
Or,
> it depends on how good you want it to look.
>
> My mandrel bender only goes to 2" :)
>
> Gary Lee
> Calgary, Canada
> gary2a@telus.net
> http://www.telusplanet.net/public/gary2a/rack/vw.htm
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