marlinstein gen 2 bumper

[Marlin]

I have it all welded and mounted. I still have to do the end caps, but I can't do that till my LED lights come in from Hong Kong. White LED running lights, and turn signals. So its all primered, looks funny white, but its starting to grow on me. I POR 15ed the front frame rail and crossmember. Neat stuff. I am speckled silver, white and ceramic red. It took a few hours to do it, but that stuff is no joke. It dries rock hard, and goes on super easy. Its very thin until it dries.
Once its all wired up, I will weld on the end caps, and rhino line the bumper and front cladding, and pending how that goes, may end up doing all of the cladding.
This bumper is much more boring looking. But now I can build a skid plate for it...

[vt_maverick]

Good work Chris, it will definitely be interesting to see how it all looks once you put the Rhinoliner on. Do you plan on doing anything to cover up the rough lower edge of the cladding where it meets the bumper bar? Maybe you could use a long section of weatherstripping to make a nice clean edge and prevent water/mud from getting between the two surfaces? Just throwing an idea out there for you...

[RamAirZ]

Looking good man, I like this stuff called Master Series better than POR15, basically the same product but ALOT cheaper lol. It's been used on some famous bridges and will withstand 15K hours of constant salt spray. I used it on a 69' Pontiac frame I did. Can't wait to see what it looks like painted!

[ZEUS]

Awe man, that sucks... It looks MUCH better than the previous one! How can I talk smack if your bumper looks good?
...yeah, you're right, I'll find a way... I think it will look pretty decent after the bedliner tho.

I like Mav's idea btw!

[Marlin]

VT_maverick, you read my mind. I am actually going to use pipe insulation, it flares out a bit and will wrap around the plastic. I wil rhino line over that, it works pretty well.

Justin, thanks....I think?

[Marlin]

Finally got all the lights wired up and mounted. PITA to cut holes through that tubing for the LEDs. I used Jack's idea (PBkid) and used hitch wiring connectors for connecting the lights, that way it is easy to take off. I even lowered my headlights down a bit, when I was blinding guys in lifted trucks, I figured I needed to do something.
I called Herculiner to see if it would bond on RTV. They said yes, but not as well as metal, then I asked about acrylic glue gun glue, they had to call me back on that, but they said yes, better than it would RTV since it dries hard. So, I used the wifey's glue gun, and sealed all the lights up, better than epoxy or RTV, and I was able to trim it to look nice. I will post some night time pics this evening of the new lighting. Still need to fit some lights into the drive light housings. That will be later on. I also need to mount up a skid plate, I got a dent in the oil pan last trip. Can't believe that is the lowest part in the front of the truck, and there is nothing in front of it...silly design.
I will try and get it painted next weekend, but I am making a junkyard run on Sat, so that is one whole day gone. Gonna get some more switches, and parts for the new family member thats coming in a month or so (93 trooper RS), thread to follow on that.

[Marlin]

Here are the pics and a few videos:

http://www.youtube.com/watch?v=G41meg8-HCE

http://www.youtube.com/watch?v=v9QQgPZfx-Q

This pic came out kind of neat, first time I used the night setting on the camera. You can see that its dark in the other pics, but in this one, it looks daylight.

[Marlin]

Wow, I must have pissed off just about everyone, no comments at all? Anyway, today is skidplate day. I am first making a front crossmember out of 2x3 1/4" angle iron. That will put it lower than the oil pan, and since I dented it last time out, I am surprised I didn't do this long ago. Stupid design. I already have the same piece up front across the where the factory tow hook frame mounts are. That will give me a nice flat, level mounting surface for the lower plate. I am also going to weld a crossbar across the bumper frame adapters. That will give the aluminum a much stronger backing. This thing should be two pieces as I see it. I will post up some pics as I move along.

[Scott Harness]

Awe man, that sucks... It looks MUCH better than the previous one! How can I talk smack if your bumper looks good?
...yeah, you're right, I'll find a way... I think it will look pretty decent after the bedliner tho.

I like Mav's idea btw!

X2 You can't call it a monster anymore

[Marlin]

X2 You can't call it a monster anymore

Yeah, now its just kind of boring. I think my last one was functionally superior to this one. Orion's style, does not help on steep approaches. The frame rails now stick out further than the bumper brackets, making them the first thing to contact rock. Not a good idea. That is why I have to fab up that cross bar. It will protect the frame rail ends and distribute the contact force over a larger area.

Skid plate idea on hold, in my typical fashion, I got under there, pulled the cross member down, cursed a bit at all the dirt falling in my eyes and mouth. Then I noticed the heat shield forward of the cat was rusted and I thought viola, thats whats been rattling. Screwed around with that, problem solved. Then I noticed one my transfer case bolts were loose, tightened that, and the checked all of em. Then I noticed that my rear drive shaft U joint was missing a bolt!! Not sure how long that his been gone? So then I dug around the garage to find one that fit, weird size, the bolt head is not much larger than the threads,so I need to go to the store...then I thought about how to mount my license plate since it isn't visible under the spare. See where this is going? I spent two hours fiddling around with stuff that I had no intention of doing. Then I took a look at the brake lines to see how hard that job was going to be since I still have yet to install my pretty SS red lines
Long story short, I built a hitch adapter to hold my license plate. Red paint is drying as we speak Put cross member back on, noticed a drip of tranny fluid on the drain bolt, but no marks in driveway, so it must be a very slow drip. No wworries there. Now its too hot to get anything else done. SO maybe next weekend, but I am supposed to go to junkyard to get all the parts folks have been asking about and some more switches.

[Marlin]

Here is the finished license plate project, I have been driving around since last year with the plate covered, no problems, I suppose it was just a matter of time.
Here are some painted bumper pics as well.

[rowhard]

I like this stuff called Master Series better than POR15,

Reads like it is pretty good stuff. http://masterseriesct.com/

[Triathlete]

So, how many offroad trips you think it will take before the plate gets ripped from that location?

Also might want to check local laws, but most states require a plate light.

[RamAirZ]

Reads like it is pretty good stuff. http://masterseriesct.com/

I love that stuff, works great and alot cheaper lol

[Marlin]

So, how many offroad trips you think it will take before the plate gets ripped from that location?

Also might want to check local laws, but most states require a plate light.

I think the plate will be fine. 1/4 angle iron isnt goin anywhere, as for the lights, well, over a year with no plate, I figure I will be ok without a light. I rarely drive at night anyway.