Custom Aluminess Power Wagon Bumper

[Fireman78]

So after seeing this truck... at Overland Expo 2011, I was more then inspired to have that bumper on my TRUCK. Problem was, this is a 2010, and mine is a 2006 , 4th gen vrs 3rd gen.. so I contacted Kenny at Aluminess with a picture and a dream...... Those guys were great, and last week I took posession of the only Power Wagon specific, 3rd generation, Aluminess bumper on planet earth. Pretty cool huh?? I will post up the install. It's a bit complicated, as I'll have to remove the winch to do it, but shouldn't be that big a deal.

 

[Fireman78]

So here was the exciting day... I was impressed at how they packed it. The box is big enough to make a chicken coop out of it. Here are some pics of me unloading.

 

[Fireman78]

Here is the Bumper inside my shed, it started DUMPING rain , so I got a bit of mud on it,, it isn't a blemish

 

[Rovertrader]

Very cool, and very envious!!

 

[Regcabguy]

I'm fortunate to live close by the factory,and visiting it is beyond being a kid in a candy store. The workers there are hard working,talented craftsmen.

While there ,a freight hauler arrived to ship a bumper to Alberta,Canada. One product,one huge crate. They really know how to pack.

 

[Fireman78]

Sorry about the crappy cell phone pics. I will get better pics as things progress. I also had to order another fairlead to go on the front of the new mumber, still waiting for that from another supplier. Also going to replace my winch cable too. It's definatly time for a new one and might as well while everything is apart.

 

[Fireman78]

Well... here it is..


Here we go..... the beginning..


taking off the factory hooks.



remove the fog light wires.

I took off my winch cable cause I needed a new one anyhow.. plus.. it decreases the winches weight by 40 or 50 pounds.


these are the tandem bolts you remove to looses the winch support.. the other side of the bolt.. not this side


These are the bolts (this is the stud) you remove to actually pull off the old bumper


progress!


The guys at Aluminess STRONGLY recommened a "friend" to help. Since I have no friends, I used my trusty tractor....
(at least no friends that wanted to drive 40 miles at 8 AM to my house to help)


these are the bolts to remove the winch from the bracket


these bolts are a PAIN IN THE A%$$


I had to give this some thought... the winch is heavy, and it needs to kinda be free floating. So I devised a two ratchet strap system on my tractor forks. I ALSO USED A FLOOR JACK!! Very important to use a floor jack!!!


another shot of my system I rigged up


so ya.. it looks goofy, but i duct taped my floor jack to a toolbox for support... hey it worked.


here is the fairlead I purchased from Tellico 4x4. it has two holes, and the bumper only has one. so I just lined it up best I could.

another shot of the fairlead


this part was a *****!!!!!!! Lining up the holes and balancing the bumper level and keeping the winch from falling down is a challege. But having awesome tractor skills and being Norwegian, I was able to do it.


after bolting the "tandem" bolts to secure the bumper, I started dealing with wiggling the winch back into place.


here is the fender well. It needs to be trimed for sure. Not really sure what kinda blade or saw to use.


finished. (sort of). I still need to do the lights and winch cable, but happy to have it on.

 

[Fireman78]

I am VERY impressed with the build quality and the fact that all the bumpers bolt holes lined up perfectly with the truck holes. Aluminess kicks A#$. (And to some degree so do I)

 

[Rovertrader]

very nice indeed!! I had to modify the Ranch Hand, drop the winch as you did, etc, and it is truely a pain!! But the winch is very secure for a factory setup...

 

[Maximus Ram]

Looks good.
From the last pic, it looks like the grille guard follows the lines of the front really well.
I have the same problem with the liners for the fender wells, also. My Buckstop Bumpers leaves a bit hanging down...have thought about either trying a sawzall, dremel , hacksaw or maybe an air saw to cut...just need to get the nerve up and do it.

 

[turbolab]

tin snips work well if you now how to use emm

 

[Fireman78]

Quick question about the lights!?... My Hella lights have white and brown wires... and the Dodge has a white/yellow and a black wire. What goes to what????? Electrical is my weakest subject I admit it.

 

[Fireman78]

Looks good.
From the last pic, it looks like the grille guard follows the lines of the front really well.
I have the same problem with the liners for the fender wells, also. My Buckstop Bumpers leaves a bit hanging down...have thought about either trying a sawzall, dremel , hacksaw or maybe an air saw to cut...just need to get the nerve up and do it.

HAHA!! Nerve is tackling this project alone! Kinda boosted my confidence a bit. I got the Hella lights to work.. I can feel the heat from 5 feet away. Can't wait to use em'... Now I gotta tackle my snorkle and air compressor.

 

[Maximus Ram]

Oh, I hear you on tackeling it alone. I did the same with my bumper, but I didn't have a tractor to help me:sombrero:..ratchet straps , floor jack and a lot of cursing is what I used:victory:

 

[chilliwak]

Nice Job Fireman. The bumper looks awesome. Can I ask what you payed for it?:Wow1: