Projects & Repairs --> Customize --> Truck Bumper
Customizing A 4x4 Truck:

Installing A Custom
Truck Bumper On A
2006 Dodge Ram 2500

 

In This Article:

The stock bumper is removed and a new heavy-duty steel bumper is hoisted into place and attached.

Related Articles:

Skill Level: 3 (Intermediate)

Time Taken: About 5 Hours

By Jim Wilk, Licensed Auto Body Technician

Start:

This custom front bumper from Road Armor isn't light or cheap. It weighs about 220 pounds and costs $1800.

 

The destination for the custom bumper: This 2006 Dodge Ram 4x4.

 

Removing The Old Bumper:

First I disconnected the wire for the fog lamps.

On this model there is one wiring connector for both fog lamps, located on the left side.

(This picture is a view from beneath the bumper, looking straight up.)

 

On each end of truck frame there are four 18 mm nuts holding the bumper to the frame.

 

With the hood opened I could reach the mounting bolts.

 

Then I removed the original bumper, which weighed about 85 pounds.

 

Because the new bumper did not come with mounting bolts, I had to use the original bolts.

 

I used an engine hoist and a lifting strap to pick up the bumper.

I found that the bumper was more stable and didn't rock back and forth as much when it was lifted up a bit.

 

At this point I was ready to assemble the new bumper with:
  • A remote-controlled winch
  • Two spacers
  • Winch cable guide

 

Mounting The Spacers:

There were three bolts on keeper plates that were held in with retainers, which were just pushed over the threads.

The white arrow points to the access hole that for the mounting bolts.

 

Since my hands were too big to fit into the access hole, I used a magnet to hold the bolt that I put into the far slot.

If you have someone with a small hand like a wife, girlfriend or child, you might not need a magnet. 

 

There are right and left spacers. The four hole side goes towards the truck frame.

I finger tightened these nuts so the mounting holes could be aligned later.

 

The winch guide had 4 mounting holes. Only the top two bolt holes are used at this stage, the bottom pair of holes are used later to mount the winch.

I used a tapered punch (red arrow) placed through the lower holes to align the parts.

If necessary, the rollers can be removed for easier access to the bolt heads.

 

Trouble...

Instead of using threaded holes in the body of the winch, the manufacturer used non-threaded holes that require nuts to connect with the mounting bolts.

BUT... these nuts didn't stay in place easily. I inserted the nuts into the bracket by using a magnet. The sides of opening prevented the nut from turning, but the nuts kept falling out whenever I lifted up the winch to install it in the bumper.

 

To keep the nuts from falling out, I packed them in with some strip caulk.

 

I positioned the winch with wood blocks and a line up punch and fastened it to the bumper, using 3/8" diameter bolts.

 

With the help of an engine hoist, we lifted this 270 pound bumper into position...

 

... It took two people to line up the bumper with the frame and get the nuts and bolts started.

We also adjusted the position so the bumper was perfectly centered on the vehicle. Then we tightened one bolt on each side.

 

Once the bumper was centered, we adjusted the height of each side.

First we wrapped the lifting strap around one end of the bumper and applied a little lifting force. Then we loosened the bolt on that side and lifted that end of the bumper up to the desired height.

Since there was only one bolt tightened on the other end of the bumper, the entire unit could pivot on that single attachment point.

Then I re-tightened the single bolt on the first side, and repeated the procedure on the other side

Once the bumper was positioned correctly, I tightened all the bolts securely.

 

This photo shows the distance between the bumper and radiator supports. This truck is at least a foot and a half longer with the new bumper.

 

Photo with the hood down.

If the vehicle owner wants to fill the gap between the bumper then he will need to buy a custom filler strip.

 

The owner will later mount the fog lights in the holes in the bumper, and connect the wiring to the winch.

 

This truck is owned by Paul Vittorelli of Traverse City, Michigan.

 

This is one mean-looking truck.

Material Costs:

  • Road Armor Front  Bumper  $1800.00 including shipping.
  • Winch  $1100.00

Work performed at R-TECH Auto Body, Traverse City, Michigan

 

More Info:

Tools Used:

  • Basic Mechanic's Tools
  • Sockets and Wrenches
  • Engine Hoist

Materials Used:

  • Bolts, 3/8-16 x 1" Long
  • Strip Caulk

Related Articles:

 

 

 

 
 
 
 
 
 
 
 
 
 
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Written December 17, 2007