End caps for single track bumpers?

Discussion in 'Discussion Forum' started by carl, Oct 9, 2018.

  1. carl

    carl True Classic

    Location:
    Virginia
    The 77 came with the usual railroad track bumper mod (single track) and I'm looking for a nice way to finish the ends.

    IMG_0524[1].JPG Pretty sure the previous owner just put some sort of vinyl tape over the ends which is actually OK but wondering what other folks did to finish the ends when doing this mod.
     
  2. kmead

    kmead True Classic

    Location:
    Michigan
    What I would do.

    CA334AD7-49F4-4810-8668-2D1D8D0C7E9D.jpeg
    I would get some .125” aluminum sheet. Cut a part to match the existing profile and then apply a radius to the outside edge of just under .120” to match the long radius along the bumper top/bottom edge.

    I would either polish it and then brush it with a scotchbrite pad or paint it if you can find a paint which is close to the existing color of the bumper beam. If you polish and brush it, you may want to clear coat it to reduce the tendency of the aluminum to oxidize.

    8F2ADC61-BD63-4AFA-8C14-2AEDB81A1EB5.jpeg
    I would make two blind, tapped holes in the reverse face.

    5720F880-32C5-4D6E-B5AF-519A34436060.jpeg
    I would then cut a piece to fit the interior of the bumper profile.

    EDA5C9A2-B773-48A8-943B-DEE103E6DE00.jpeg
    I would then drill two through holes to allow using an L bracket to run screws through the bracket the inner locator and then into blind holes of the end cap.

    10B40CB1-20F5-4444-A12A-21669D84476E.jpeg

    The assembly would then be bolted to the bumper through two holes in the bottom of the bumper beam.
     
    Last edited: Oct 10, 2018
  3. Daniel Forest

    Daniel Forest True Classic

    Location:
    Montreal,Canada
    Karl,

    It seems you got a good idea... but somebody did it before. I got something similar. I can't say if it's a "one-off" or sold by a Fiat specialist, but here what I got on a 1975 parts car. I plan to polish it, give it some TLC and put it in the front of my 1980 black car.

    This is a modified front blade. It had been shortened in the middle so it will clear the 1975 front lights. (If it's not clear, I could take a pic while hanging it out in front of the car). I can't tell you how it was done, even the PO didn't, it was already on the car when he bought it.
    20181009_192421.jpg

    Here is a pic of the middle. On the top, there are no visible bolts, just in front and underneath.
    20181009_192538.jpg

    And view from Inside:
    20181009_192549.jpg
     
  4. kmead

    kmead True Classic

    Location:
    Michigan
    I tend to prefer not seeing fasteners on visual parts, thus the extra bits suggested versus seeing the heads of the screws.
     
  5. Daniel Forest

    Daniel Forest True Classic

    Location:
    Montreal,Canada
    Yup, but there was probably a black tape in front and the ones underneath, well at our age we are not going to bend often to check!

    I kind of like the side ones... I always like nice mechanical things. It's a matter of taste.
     
    kmead likes this.
  6. carl

    carl True Classic

    Location:
    Virginia
    Karl, really nice end caps and all the guys on the TV mod shops could make it but how does a guy with a bench vise and drill press make those nice rounded edges? I may just try one with flat edges, would probably work.
     
  7. kmead

    kmead True Classic

    Location:
    Michigan
    You spent your apprenticeship filing edges didn’t you?

    If one is careful and mounts the part on a lager object you can use a router to apply radii to aluminum.

    Alternatively you could make the parts out of acrylic and then paint them. Acrylic machines very well and is pretty tough in an application like this. ABS would be an excellent be an even easier material to work as another alternative.

    Square edges would be fine too.

    I am too used to having a model maker at my beck and call for work
     
    Last edited: Oct 10, 2018
  8. toddr124

    toddr124 Hagerstown, MD

    Location:
    Hagerstown, MD
    Make a template out of cardboard for the inside and outside ends of the bumper. I have plastic, bandsaw and grinder. We can make end caps when you come to get the carpet and parts.
     
    kmead likes this.
  9. carl

    carl True Classic

    Location:
    Virginia
    I'm waiting for the woodworking crowd to jump in and say how easy it is to make one from wood.
    K, not everyone has a router either!
     
  10. Pete Whitstone

    Pete Whitstone True Classic

    Location:
    McKinney, TX
    Aluminum is not that much harder than wood. With some manual effort, this could be cut out with a hacksaw and nicely finished with a belt sander.

    Pete
     
    kmead likes this.
  11. dllubin

    dllubin True Classic

    Great! Now we can worry about termites as well as rust.
     
    Daniel Forest and kmead like this.
  12. carl

    carl True Classic

    Location:
    Virginia
    I'm going to have my professional wedding cake maker daughter make me some out of cake...that way we can worry about ants too!
    And to put this in context she is the one who bloodied my rat X.
     
  13. toddr124

    toddr124 Hagerstown, MD

    Location:
    Hagerstown, MD
    Now you are just coming up with half baked ideas.
     
  14. carl

    carl True Classic

    Location:
    Virginia
    It's just icing on the cake, bub.
     

Share This Page

  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.
    Dismiss Notice