I managed to tack and weld out the 3 main parts of the bumper. It was a little bit of a struggle pulling the bottom plate into position (inside edge to inside edge with about a 1/16″ overlap). I ended up TIG welding all the joints. I didn’t like the MIG welds I made on a test piece (I don’t have many hours on the machine). I’m not saying that my TIG welds are very good, but at least I got some practice. In any case, I’m going to grind down the welds to make a rounded or at least a beveled corner. I haven’t finished fairing the free edges of the top and bottom plates yet.
Tacked up.
Outside tacks on the face to bottom plate joint.
Inside tacks on top plate to face plate.
Then on to my inconsistent and amateurish weld out.
All done, top and bottom plate welded on.
I’m rubbish at estimating weights, but I’d guess around 10 kg as is.
shooftie 
#1 by famillysyncro on August 2, 2013 - 9:43 pm
Good work Alistair, as usual.
I’ll try to hide that post to the madam or you’ll get me in trouble…..
#2 by albell on August 2, 2013 - 9:50 pm
She hasn’t seen it, I’ll spring it on her when it is on the van. I won’t say anything, perhaps she won’t notice?
ab