Attaching Tube Bumper

[thebearded1]

Alright looking to see what ideas you all have. It's always nice when people from the outside take a look with fresh eyes. I have an aluminum round tube i'm using as a rear bumper and I notched the frame ends for it to set into. What would be the best way to mount it you think? The bottoms will be welded up when I'm done. It's a pretty hefty piece that is 34" long and weighs 7 lbs


One thought was to cut a piece of flat stock to fit in the frame, drill hole for bolt and weld on the back side. Then insert the head end with the flat stock into the frame while bolted through the bumper and then plug weld that piece of flat stock to the frame. Highly accurate CAD drawing below. This would probably be the most secure but I feel like it's going to be tough getting the flat stock to line up and if those bolts ever get messed up that's going to be a PITA to replace them.


Other option was to use a small bolt down through the top of the frame and either tap the aluminum to thread the bolt into or try and get a nut inside the tube onto that bolt since the bolt would only be about 3" in from the end.

Thanks
Gene

 

[LongJohn]

Can you weld aluminum? I would weld two 1/4" thick straps with two threaded holes that could be bolted to the inside frame rails with button head bolts and cap the tube ends. That way the " bumper" would look like it was floating unless you really look hard.

 

[thebearded1]

Can you weld aluminum? I would weld two 1/4" thick straps with two threaded holes that could be bolted to the inside frame rails with button head bolts and cap the tube ends. That way the " bumper" would look like it was floating unless you really look hard.

I can not but my friend can. I will have to see if either of us have any aluminum stock that would work.