Right tube, wrong bender. The harbor freight bender is for pipe not tube. DOM is proper material for what your doing. Look on youtube for ways to modify the pipe bender to work with tube or find some one with an actual tube bender to borrow.

 

Tom,

You and I both have the HF 12K winch. This is how I got my custom bumper fab'd to accommodate the 12K winch without having to mess around with the grill. My Disco has the Terra Firma 2" lift. The approach angle works fine for me.

 

That's a pretty sweet bumper! I even like the color match. Probably get scratched to hell and back if really offroaded hard but it looks good

 

The painter used a heavy-duty clear coat which is popular in the commercial truck industry. It has held out well from a few NW Overland Rally off-road excursions.

I am planning to add an additional 3M Paint Defender coating for added protection against small road chips.

In the end, I recognize the Disco is intended to be an off-road vehicle. I am not sweating it too much with the occasional scratches as we encounter lots of brush and pine vegetation in the Pacific NW, aka "Pacific NW pin-stripping"

 

acg;

very nice bumper indeed; and by keep the winch low you do not block your airflow

 

Acg nice work, did you cut the stock brush guard and weld to the bumper? Saw that done by another did not look as good

Rover right , I did see on YouTube where a few made it work either making additional shoes or by packing wet sand in the tubing

 

We created a new brush guard with rolled tubes and welded it onto the new bumper.

It was more economical to sell the factory brush guard to fund the custom bumper project.

 

How did you bend your tubing?

 

The fab shop has a hydraulic tube roller machine. Something like this may also work.... just takes more time to make sure the bends on both the right and left side tubing match up:

 

Yeah tried a local muffler shop, their old machine did bend it but put shoe marks on the inside of the bend and looks like crap

Was gonna return the hf bender,have the boxes but lost the receipt