Heavy Duty Bumpers for Expedition/Overland Use: Practical Necessity or Superfluous an

Mundo4x4Casa

West slope, N. Ser. Nev.
It's obvious that there are many approaches to bumpers as there are many requirements for use. I drew my personal line on the bumper by only having as much as I need according to my experience (in about 2 million miles in 14 four wheel drives). Currently I have an '82 CJ8 rockcrawler, a '99 XJ winter car, a '11 Jeep Cherokee, and my '01Dodge/Cummins/Lance TC. What experience? For those of you that have ever lacked a winch point, or hit a bull elk @ 45 mph, or pulled the front bumper right off the rig with the winch, it tends to narrow your search. I am in the lighter-is-better school of winch bumpers. Since my backpacking days, I'm always looking to not carry any weight that I do not absolutely need. Recovery gear is an exception. You never have enough recovery gear. My latest 'roo bar'/bovine deflector started as a warn winch carrier for my 15K pound winch and expanded from there. I welded on some medium weight wings, some using 4330 ChroMoly driveshaft tubing and added a radiator saver, a front receiver hitch, and a pair of cement mixer 26K pound D rings. I did not remove the factory pumper (as tinky as it is) so the winch sticks out farther than I would like, but it's no worse than the breakover angle on the Dodge so no harm no foul. I also trimmed the front fenders a bit to gain some pull up room for tires getting over boulders.


Most of the rigs i see above, IMHO, are not true 'expedition' vehicles but are great looking,
1. rock crawlers
2. multi purpose vehicles
3. pick up trucks with no cargo
4. nice trophy trucks
5. weekend warriors with a nice RTT
6. four wheel drives
So, what entails an 'expedition' vehicle?
The ability to travel over poor roads in a rather simple, not electronically complex rig (a 12 valve Cummins would be a good choice), probably in 3rd world countries following rickety old diesel 10 wheelers for weeks on end in desert heat or arctic cold and snow and live, sleep, eat, drink, shower, work, with little to no set up and have you and the entire rig 'survive' the expedition. A good point is to have more drivetrain than your engine can break. A manual trans, locking hubs, and traction aiding devices are good. Survival would include an array of self-extraction, self-recovery gear: Winch, snatch block, sand anchor, 10 foot chain one end with a very large hook, other end a slot hook, cat choker, 4 D rings, tree saver, 20K pound strap, 30K pound strap, 1K pound ratchet strap or two, 5 foot hi lift jack, jack board, 12 ton bottle jack, 4 ton scissor jack, 4 foot breaker bar, 3 foot screwdriver/prybar, on board welder and supplies, 30 pound CO2 tank and 12v high volume air compressor for airing up tires. If it's a truck camper of any kind, a tray or three point flatbed will help you weather the off-road storm without pulling it apart.
An ability to get at least 600 miles on the fuel you carry on the rig and at least a month on the fuel inside the domicile for cooking, heating, etc. After about 2006 or so, many of the big 3 diesel trucks cannot use Mexican diesel and I'm assuming sud amerika diesel. Those pesky soot bags and pee canisters get in the way.
Space for two spare tires/wheels, a Safety Seal, on rim, tire repair kit, a gas generator or adequate solar power, two weeks worth of clothing, tools, spare parts enough to get you to civilization and the ability to do it yourself if you have to.
My first trip to Baja was in 1965 in a 1949 Willys Ute Wagon with a big honkin Chevy V-8, with 5.38 gears and a Studebaker 33% overdrive. No electronic anything. A single, centered tail light. The stock chrome front bumper was solid and the rear 6 inch channel iron bumper said, PASS (arrow down) as it was one of the first spring-over-axle jobs I'd done. My new bride and I slept in the back in sleeping bags after days of driving over bumpy, silty trails, averaging 10 mph. The dust/silt got into everything. We had an engine fire and I had to re wire some of the engine electrical to get back home. We had 4 jeep gas cans strapped on the sides and rear and a spare fuel tank. Mexican gas had just doubled to 16 cents a gallon. Man, was that primitive. At least I could fix anything short of armageddon it was so primitive.
It was good to see all the variations on a theme with your bumpers. It gives me more ideas.
regards, as always, jefe
 

HARDTRAILZ

Certified
Nice opinion on what an "Expedition" vehicle is, but really it is just your opinion. Just like my opinion that you built a glorified brush guard over a factory bumper and not a heavy duty bumper.
 

SGTCap

Adventurer
Nice opinion on what an "Expedition" vehicle is, but really it is just your opinion. Just like my opinion that you built a glorified brush guard over a factory bumper and not a heavy duty bumper.

I don't care who you are, that's funny right there.
 

Mundo4x4Casa

West slope, N. Ser. Nev.
hardtrails,
I cannot disagree with your assessment. It's just that my opinion is more humble than yours.
I did hit a 300 pound bull elk near Ely NV. one night and lived to tell about it. I thought i was going to die. It was like hitting a brick wall with a 10,000 pound rolling sled. It did not come over the hood and kill the radiator. that's all i could want out of a flimsy little bumper. The bumper was JUST enough, had a little give, but it's the center plates on the carrier that saved me from an ignominious death.



Nice trail truck you have there. 8<)
regards, as always, jefe
 
Last edited:

psyfalcon

New member
Wouldn't the reinforced bumper just transmit all the force to the frame? Even economy cars have a reinforced bumper under all the plastic and foam. Might cost more to be replaced, but straightening a frame isn't the easiest thing either.
 

HARDTRAILZ

Certified
hardtrails,
I cannot disagree with your assessment. It's just that my opinion is more humble than yours.
I did hit a 300 pound bull elk near Ely NV. one night and lived to tell about it. I thought i was going to die. It was like hitting a brick wall with a 10,000 pound rolling sled. It did not come over the hood and kill the radiator. that's all i could want out of a flimsy little bumper. The bumper was JUST enough, had a little give, but it's the center plates on the carrier that saved me from an ignominious death.

Nice trail truck you have there. 8<)
regards, as always, jefe

Glad it kept you safe. That is why we build what we build.

Your opinion is far from humble in your post. Alienates over 90% of the members here.

I am glad to see you gave my rig its own category. I built it to be different. I built it to allow me to DD in the city, commute to work 130 miles, keep my family safe n mobile in any weather, hit moderate to difficult trails, be easy to park, haul a trailer or camper, get good fuel economy, or allow me to take expeditions occasionally. I think it came out as a solid expedition portal worthy vehicle. It sure does not meet your high n mighty standards; however it does all I want it to do, no matter what you call it.
 

Buliwyf

Viking with a Hammer
It looks like the Road Rhino bumpers are about the only reasonably priced bumpers out there for Fullsize Fords. $1000 built. About $600 center section built only, you weld the rest.
-
I'm sorry, I can't pay $3000 for a bumper I might use once. I can get bumpers from a "Take Off" yard for $300.
-
I'm considering a Warn Transformer mount with some "brush guards" added as well. Should be enough to keep deer out of my radiator. It's hard to build a brush guard setup that isn't a "damage multiplier". Apparently yours, actually worked ok.
 
Last edited:

Buliwyf

Viking with a Hammer
Wouldn't the reinforced bumper just transmit all the force to the frame? Even economy cars have a reinforced bumper under all the plastic and foam. Might cost more to be replaced, but straightening a frame isn't the easiest thing either.

Yes. An offroad bumper destroys a trucks frame in huge crashes. But that is debateable, because 3/16" plate will bend a crush a bit before the frame bends. And would a stock bumper have saved the frame? Noone can tell for sure. It helps in fender benders, but my stock bumper is decent at those. It also significantly decreases your safety in huge hits from immovable objects. (like a tree, bridge support, or edge of concrete freeway divider block)
-
It's ok if the bumper is stronger to direct center impacts. It's not ok if the bumper applys serious leverage to the frame from a corner hit and tweaks it. Some frames are stonger than others as well. My Superduty's frame is about as beefy as they get. So I'll bet that a Deer or Prius shouldn't hurt it with a decent bumper on.
-
Bottom line: There is going to be a trade off somewhere. It's just hard to pin point it. Keep in mind. Frames are indeed engineered to fail in crashes. (The Ford Raptor is the best safety example that comes to mind)
 

crazy

Adventurer
It's obvious that there are many approaches to bumpers as there are many requirements for use. I drew my personal line on the bumper by only having as much as I need according to my experience (in about 2 million miles in 14 four wheel drives). Currently I have an '82 CJ8 rockcrawler, a '99 XJ winter car, a '11 Jeep Cherokee, and my '01Dodge/Cummins/Lance TC. What experience? For those of you that have ever lacked a winch point, or hit a bull elk @ 45 mph, or pulled the front bumper right off the rig with the winch, it tends to narrow your search. I am in the lighter-is-better school of winch bumpers. Since my backpacking days, I'm always looking to not carry any weight that I do not absolutely need. Recovery gear is an exception. You never have enough recovery gear. My latest 'roo bar'/bovine deflector started as a warn winch carrier for my 15K pound winch and expanded from there. I welded on some medium weight wings, some using 4330 ChroMoly driveshaft tubing and added a radiator saver, a front receiver hitch, and a pair of cement mixer 26K pound D rings. I did not remove the factory pumper (as tinky as it is) so the winch sticks out farther than I would like, but it's no worse than the breakover angle on the Dodge so no harm no foul. I also trimmed the front fenders a bit to gain some pull up room for tires getting over boulders.


Most of the rigs i see above, IMHO, are not true 'expedition' vehicles but are great looking,
1. rock crawlers
2. multi purpose vehicles
3. pick up trucks with no cargo
4. nice trophy trucks
5. weekend warriors with a nice RTT
6. four wheel drives
So, what entails an 'expedition' vehicle?
The ability to travel over poor roads in a rather simple, not electronically complex rig (a 12 valve Cummins would be a good choice), probably in 3rd world countries following rickety old diesel 10 wheelers for weeks on end in desert heat or arctic cold and snow and live, sleep, eat, drink, shower, work, with little to no set up and have you and the entire rig 'survive' the expedition. A good point is to have more drivetrain than your engine can break. A manual trans, locking hubs, and traction aiding devices are good. Survival would include an array of self-extraction, self-recovery gear: Winch, snatch block, sand anchor, 10 foot chain one end with a very large hook, other end a slot hook, cat choker, 4 D rings, tree saver, 20K pound strap, 30K pound strap, 1K pound ratchet strap or two, 5 foot hi lift jack, jack board, 12 ton bottle jack, 4 ton scissor jack, 4 foot breaker bar, 3 foot screwdriver/prybar, on board welder and supplies, 30 pound CO2 tank and 12v high volume air compressor for airing up tires. If it's a truck camper of any kind, a tray or three point flatbed will help you weather the off-road storm without pulling it apart.
An ability to get at least 600 miles on the fuel you carry on the rig and at least a month on the fuel inside the domicile for cooking, heating, etc. After about 2006 or so, many of the big 3 diesel trucks cannot use Mexican diesel and I'm assuming sud amerika diesel. Those pesky soot bags and pee canisters get in the way.
Space for two spare tires/wheels, a Safety Seal, on rim, tire repair kit, a gas generator or adequate solar power, two weeks worth of clothing, tools, spare parts enough to get you to civilization and the ability to do it yourself if you have to.
My first trip to Baja was in 1965 in a 1949 Willys Ute Wagon with a big honkin Chevy V-8, with 5.38 gears and a Studebaker 33% overdrive. No electronic anything. A single, centered tail light. The stock chrome front bumper was solid and the rear 6 inch channel iron bumper said, PASS (arrow down) as it was one of the first spring-over-axle jobs I'd done. My new bride and I slept in the back in sleeping bags after days of driving over bumpy, silty trails, averaging 10 mph. The dust/silt got into everything. We had an engine fire and I had to re wire some of the engine electrical to get back home. We had 4 jeep gas cans strapped on the sides and rear and a spare fuel tank. Mexican gas had just doubled to 16 cents a gallon. Man, was that primitive. At least I could fix anything short of armageddon it was so primitive.
It was good to see all the variations on a theme with your bumpers. It gives me more ideas.
regards, as always, jefe

Nice story. Does not changing my underwear for three weeks make my truck a real expedition rig? I don't have a bigass bumper yet but will soon to compensate for smaller body parts.

You talk about simple, non-electronic, follow a donkey down a lonely road simple rig that can be fixed with bubblegum and baling wire. Your 2001 Cummins has a VP44 injection pump that will take a dump when your lift pump fails. What are you going to do then? Carry a spare $2000 injection pump with your self-extraction, self-recovery gear?:ylsmoke:
 

Mundo4x4Casa

West slope, N. Ser. Nev.
Bulywif,
I fabbed and welded on ears to the top part of the Warn transformer side plates with the big tube on top. My guess is it was about neck high on the Elk. Just enough to repel. The carrier itself is so H.D. that i consider it another crossmember to the frame. The lower diagonal pipes are thick wall 4330 Cr.Mol. I also have the aftermarket steering box brace which is another defacto crossmember as it tightens up the twisting of the stock Dodge frame. And it did twist.
The Warn transformer seems to have a much better connection and sturdy factor with the newer Fords because of your great front frame members. Good luck on your pursuit.
jefe
 

Mundo4x4Casa

West slope, N. Ser. Nev.
Crazy,
Underwear? We doan' need no stinking underwear! You really got me going with that one. I didn't say i had the perfect Expo rig, only describing the most trouble-free starting place. Me thinks the problem is that this site has slowly and inexorably changed from an actual Expedition site (which i describe above, in my humble opinion) to an Adventure Travel site, which is a run-whatcha-brung site, which is fine with me. I've owned a whole lot of run-whatcha-brung rigs over the years. There are places on here that actually have to do with Expedition travel and I'm constantly reading over people's posts, like Hackney's. What a wealth of knowledge that guy is. My neighbors are Monica and Gary Wescott of the Turtle Expedition, who I have followed for 40 years.
I am aware, big time of the VP-44 woes on the Cummins/GenII engines. I've never lost a VP (am running the one that came with this thing) but have replaced the real culprit to the injector pump blues which is the lift pump. As a precaution I moved an upgraded version down to the frame so it became a pusher not a sucker, ditching much of the heat and vibration, and carry (2) replacement lift pumps under the driver's seat. I also installed a fuel pressure IDIOT light, which warns me if the pressure drops below 5 pounds. I have had 'dead pedal' a couple time when I ran out of fuel (because the gage said I had plenty). Bled the system and primed it and it started right up. No VP-44 failure. I'm at the expected life's end of the VP-44 @ 150K mi. and will replace it with the 'Fedex Pump" available from Industrial Injection Supply in Utah. Directly across the lane from me is another '01 Cummins owner who has 378K miles on his original injector pump. If you know what you are doing, stay meticulously clean, it's a chore but not impossible to change a VP-44 along the side of the road....if you had to. I hope I never have to.
My bride and I are planning a four month, around the U.S. clockwise, only in border states, trip around the country in Cabeza de Vaca. I think I do have a rig capable of staying out that long without divorce proceedings.
regards, as always, jefe
 

crazy

Adventurer
OK, you're prepared for the lonely goat trail.

Not exactly following on the "Fedex pump".
 
Last edited:

Mundo4x4Casa

West slope, N. Ser. Nev.
crazed one,
this is the link:
http://www.industrialinjection.com/shop/category/pumps/dodge-injection-pumps/
for a time they put together a pump with added H.P. and TQ for the Cummins engines in Fedex trucks with no wire. I like no wire. Keeps the turbo cooler and the drivetrain in one piece. Nothing cheap about this pump. I think they are up to $2K now. I'm thinking now Fedex is reducing their diesel engines because of the outcry over the wall-to-wall noise they make. The '01/'02 Gen II HO CTD engines are the noisiest of the bunch.
Yep, goat trail it is. On our proposed 4 month trip thru all the boundary states, we will mix it up with N.P.'s, N.F.'s, state campgrounds, county campgrounds, boondocking, dry camping, fish and wildlife preserves, stealth camping in cities, and a once-a-week high-bucks hotel, all between September 1st and January 1st. The other stipulation is to camp at every beach both east and west that allows camping actually on the sand, like Pismo, as I have these big high floatation tires and on-board air that serve me well on beach sand and dunes.
jefe
 

kojackJKU

Autism Family Travellers!
I am keeping my stock bumpers on my jeep and modifying them to suit me. Front is getting an internal winch mount, vdp high clearance end caps and skid row skid plates. Rear is getting led lights flush mounted as well as my plug for my pop up flush mounted.

Sent from my A210 using Tapatalk
 

Forum statistics

Threads
189,807
Messages
2,921,121
Members
232,931
Latest member
Northandfree
Top