Here are the photos on Picasa from my rear bumper build.
https://picasaweb.google.com/1022624...perFabrication
It is a simple 2x4 3/16" boxed steel with steel tread plate.
Cost is about $250 for the parts. The boxed steel beam 2"x4" x 16ft is $100 + another $150 in grinding accessories (wire wheel,cutting wheels, welding wire, primer, paint, bolts, Reese receiver hitch. Multiple trips to the hardware store for hole saws.

Full Factory features include

• Rear Fog lights/reverse lights
• PDC Park Distance Control sensors
• Integrated Class III Trailer hitch

My cool upgrades are:

• Side step micro nerf steps
• Factory side marker turn signal blinker

You must trim the L/R of your rear quarter panels which would deter many from the project, as it is a scary start. But once mocked up and then finally installed it greatly increases the exit angle of the vehicle. If you resonator is already removed it looks much better. There are many steps to this project and too many to list, such as either doing away with or relocating mounts for the rear mud flaps.

I never thought I had metal working skills but when a nice rear bumper is $1200. I'll make them up as I go alone.
This was developed off of Disco Mikes simple rear bumper from pictures. I can forward the email.
Also I will make a writeup for this as time permits. I'm still am working on it each night. Now ready to well the tread plate and the additional arms for the trailer hitch. Plus side supports.



Done welding the basic bumper and mocking up the top tread plate and side steps



This is about one week ago, before the Park Distance Control sensors are installed




Fitting the sides and checking for how far out from the rear should come. Also checking to see if the tread plate will clear when the rear gate is opened & closed.



Bending the rear light guards from solid 1/2" round bar.


Welded the light guards all the way around on the bumper. So MUCH Grinding to make them look nice


Holes cut for the Park Distance Sensors


Trailer hitch measured and welded, with one plate of steel to raise it to even height between the top and bottom of the bumper.






Fitting the bumper to the rear end. Checking to see that the 1999 trim strip would nicely transition to the bumper. In the picture it is just sitting there.

 

Great job! Would you mind sending or posting more photos and perhaps plans/instructions/measurements? I'm looking at building one very soon and would appreciate the help!

 

god bless you. makes me feel better about my britpart bumper costing $362. lets see some pics of it mounted!

 

I would love to see a write up and drawings

 

Do any of you engineers out there know of an AutoCad type freeware I could download to draw this up!

 

google sketchup