Full Custom Bumper and Chase Rack Build - 1995 K1500 3" Body Lift

[TorchRed77Vette]

Well I decided it was time to spruce up the "Do Work" Truck. Luckily, I own a small fabrication shop so I have some fun tools that I have either built myself, like my CNC Plasma Table, or hacked, like a xbox Kinect 3D scanner. Thought I'd document the builds here in case y'all are interested in the process and try to get some feedback from everyone at the same time. Who knows, maybe I could even build a few of them if people here are interested, I know the choices for our body style are a little dated, and coices for a truck with a body lift are slim at that.

First off, I am a Mechanical Design Engineer so I will be doing the design in the computer first...just the way I work, so if you are a garage mechanic bare with me. But, like the thread title said, its a 1995 Chevy 1500 Z71 ext Cab with a 3" body lift. I like the prerunner look, but am going to beef it up a little, cause its a Chevy.

First I took the bumpers off so that I could get a good scan of the existing mounting point. Here are some pics of the before:

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That's weird this photo is right side up on my computer, but upside down on my phone

 

[TorchRed77Vette]

Starting with the front bumper. Like I said before, I removed the stock bumpers to get it ready for the 3d Scan. I used a x box 360 kinect sensor attached to my windows laptop to get a general scan of the front end. I used Reconstructme to do the scanning...just google "xbox kinect reconstructme" for the whole process of installing the correct drivers and such. The scan wasn't perfect but it was enough to give me something to start designing the bumper around in the computer. If you're going to do it...it takes some playing with, and remember its pushing the technology.

The grill looks funny on the scan cause i ended up covering it because the shiny chrome grill and headlights kept messing with the scan. But as you can see, the undercarriage came in decent.

3D Scan Image:

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[TorchRed77Vette]

I was able to get a jump on designing the bumper but had a few variations that i would like some feedback on if anyone reads this before i start fabricating .

I'm diggin my general design, but have some different feelings on the side close outs. I have three options to choose from:

1.Cutting them out of aluminum and leave it raw to match the skid plate, these would be bolted on.
2.Cutting them out of steel and painting them black with the rest, these would be welded.
3.No close out, as shown on the driver side. Only drawback here is it will show the body lift block and body support bracket pretty clearly.

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[camaroman101]

Really cool project, I'd definitely have to choose the close outs but between the two I'm leaning more towards the black steel.

 

[TorchRed77Vette]

Ok one last thing for the night.....don't burn me at the stake, but I kind of dig the ford raptor grill....I'm thinking of doing something similar. It would involve cutting the center portion of my existing grill out and replacing it with my design.

I was thinking either "CHEVY" in a similar font, or just a big ass bowtie. If I did the bow tie, i would probably paint the the grill black then mount rivet an aluminum bow tie on so that it really stands out. Here are some examples:

CHEVY GRILL

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BOWTIE

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[Bob L]

I like the chevy grill

 

[Cokeman95]

I was able to get a jump on designing the bumper but had a few variations that i would like some feedback on if anyone reads this before i start fabricating .

I'm diggin my general design, but have some different feelings on the side close outs. I have three options to choose from:

1.Cutting them out of aluminum and leave it raw to match the skid plate, these would be bolted on.
2.Cutting them out of steel and painting them black with the rest, these would be welded.
3.No close out, as shown on the driver side. Only drawback here is it will show the body lift block and body support bracket pretty clearly.

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#2 for me.

Ok one last thing for the night.....don't burn me at the stake, but I kind of dig the ford raptor grill....I'm thinking of doing something similar. It would involve cutting the center portion of my existing grill out and replacing it with my design.

I was thinking either "CHEVY" in a similar font, or just a big ass bowtie. If I did the bow tie, i would probably paint the the grill black then mount rivet an aluminum bow tie on so that it really stands out. Here are some examples:

CHEVY GRILL

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BOWTIE

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I like the Chevy one

Sent from my SAMSUNG-SM-G900A using Tapatalk

 

[TorchRed77Vette]

Cool. Thanks for the opinions. I think I agree with y'all too. After looking at the pics for a day think I'm going black closeouts and the Chevy grill. Think I'll begin some fab today.

 

[95C1500]

Very cool thread. I know you've already decided but I'll toss my opinion in anyways, black and "Chevy"

 

[mars2878]

black & Chevy.

would it be easier to use the grille insert that your in a GMC grille shell? It already has the big grille opening, might be less work.