Projects like this always take longer than expected. Yesterday poured rain all day before it switched to snow, and we don't weld or use the plasma inside the shop due to fire hazards (lots of farm chemicals and... things), so progress was slow.
Here's the 2x6x3/16" tube mocked up
My Uncle was feeling real ambitious and eager to help, and we spent a few hours yesterday figuring out how to make the brackets. A few notches needed to be made in the 4x4x1/4" angle iron to fit around a few obstacles, and getting holes drilled in the perfect spot is always a fun challenge. I'm also aware I have cancer under my truck. It's lived its whole life in Utah where they salt the **** out of the roads, and although I crawl under it with a heated pressure washer often you can see it's taking a toll. I plan on removing the bed this summer, getting all the rust off and then POR-15 and fluidfilm.
On each side, I'm using the two bolts on the vertical the bumper used and the two underneath the hitch used. The extra length in my brackets are for more support for tongue weight. The notch at the back is to go around a rivet on the frame. I welded the bumper on just 2 1/8" off the end of the frame rails to keep it as high and tight as possible. These two photos are before holes were drilled-
2x6x3/16" box tube capped with some 3/16" plate, and 2" receiver welded in. Flush mount, barely enough room to reach behind a squeeze the hitch pin in.
Brackets welded on. It looks so damn good on the truck that I forgot to snap a photo!
And here's the prime rib we ate for dinner tonight!
Still need to add a few 3/8" gussets around the back side of the receiver, which I will probably punch holes in with the plasma to hook chains onto. Need to weld the 1.75" round tube onto the low point of where I capped the box tube. Brace it with a piece of 1x2x3/16 box tube back to the bracket. Cut the bedside to match the angle and it will be done. Really happy with how it's turning out so far... 8" of additional ground clearance and I think it's going to be within a few pounds of the 110 lbs the old hitch/bumper weighed.
Then I have a paint dilemma. Usually I'd love to paint it with my typical few coats of Rustoleum self-etching primer and then half a dozen coats of bedliner, but it's a high of 35 degrees out and I'd have to paint outside. I'm worried the paint isn't going to cure. I'm debating powdercoating it, but it's obviously expensive and has the possibility of getting scratched and needing to be touched up. No matter what I need to get enough paint on it to drive from Boise to Salt Lake next week and keep it from rusting. Anyone have experience painting metal in the cold?