Blazer/Jimmy front push bar build

[hemi43]

I finally got around to making a push bar, but first must thank Yukon Jack and Lieferson for their help, because that saved me hours of work. Once I have a final design of the main bracket shape, I will offer a DXF file of it for anyone that would like it. This file can then be taken to anyone with a CNC plasma table or water jet.

The original drawing is very close to the final shape, but I want to tweak the area around the bumper so that it has more of an even gap. Unfortunately, this design does require drilling one hole per side into the frame rail. I will try and figure out a way to use the existing hole in this area, but by doing so it may make it difficult to install. Time will tell.
Here's a few pictures of what I've done so far. I first printed the shape on paper to make sure the scale was correct, then cut some scrap 18g sheet metal. The final piece will be cut from 3/8 plate.

I built my CNC table a few years ago using a CandCNC controller and an old Dell PC running windows XP and Mach3. One of the best things I ever built !! I can think of a part, and have it in my hand within 10 minutes.

[Yukon Jack]

Very cool. Will enjoy this build for sure.

[DeadheadNM]

Thanks for sharing. Would be great if the mount bracket holes were aligned with the existing holes on 72 frames designed for tow hooks.

[A1971Blazer]

Put me down for the .dxf file please....

[hemi43]

Originally Posted by DeadheadNM

Thanks for sharing. Would be great if the mount bracket holes were aligned with the existing holes on 72 frames designed for tow hooks.

I'm not sure if all year frames were the same in that area, but my truck is a 70 and that's all I have to go with. When you say "tow hook holes", I assume you mean the oval hole. I think the problem with using this hole is that it's not located far enough away from the other mounting hole which is the the same as the top bolt that holds the bumper on. Another issue that I see using this hole is that the bracket will have to be modified to reach this hole and then it may be difficult to get the bracket on because of interference. Like I said, time will tell and I'll figure it out.

[DeadheadNM]

Check. For 72 GM included frame holes specifically for tow hooks apart from the oval hole.

[stangtjk]

Here are what the holes look like on my 72. Not sure if all of them are original.

[Lieferson]

Ill climb up under my truck today and snag a picture of how mine bolts up to the slot in the frame. One thing i would change on mine is the top cross bar. I love how beefy the whole thing is, but it covers up the bowtie! Also, making the bottom bar flat or some light tabs for aux lighting would be a nice touch

[hemi43]

Originally Posted by Lieferson

Ill climb up under my truck today and snag a picture of how mine bolts up to the slot in the frame. One thing i would change on mine is the top cross bar. I love how beefy the whole thing is, but it covers up the bowtie! Also, making the bottom bar flat or some light tabs for aux lighting would be a nice touch

Yeah, I know what you mean about the top bar. It would cover the "chevrolet "script on my 70 grille. I will put some sort of tab for lighting, but first have to figure out what I want for lights. I'm even thinking of using a 24" LED light bar, but it may look too modern for the truck.

[hemi43]

Originally Posted by stangtjk

Here are what the holes look like on my 72. Not sure if all of them are original.

That would make life easier !! I'm reluctant to drill my frame, but that may be the best way to go. I'm also thinking about using 2 bolts there and eliminating the one that uses the bumper bolt. I realize if this push bar was ever used as intended, it would have too much leverage in that area, but this will be more cosmetic and I don't want to mark up the chrome on the front of the bumper.

[stangtjk]

If going mainly for cosmetics I think it might look cool to use two pieces of 3/16" on each side instead of one piece of 3/8. Space the 3/16 plates out 2.5" or so with a strip across the front to box it in. Kinda mimick the look of the stock bumper guards but taller with a push bar. Would be a good bit more fab work but would add a nice touch.

[Lieferson]

I plan on running 2 of the KC Gravity series 4x6 led lights. they look old school with modern LED technology! just a little spendy. 300$ or so

[hemi43]

I'm working on two different files. The first one is the same shape as Yukon Jack's push bar. http://yuk0njack.com/70blazer/brushguard/p3210345.jpg

The second one is much shorter and won't hide the Chev logo on the grille, and looks kinda like Lieferson's except the top bar is a couple inches lower. http://67-72chevytrucks.com/vboard/attachment.php?attachmentid=1643942&stc=1&d=1492633031 This is probably the one I will finally build. I also played around with the frame mounting area so that the factory oval hole can be used for mounting. I still need to cut a full size template to make sure everything mounts properly.

[Lieferson]

I was able to get a couple pictures of how mine mounts up and how flush it is with the front bumper

[hemi43]

I finalized the shape of the side bar. Fits real good and picks up the oval hole, and slides into place without any interference so the bumper doesn't have to be unbolted. I'm most likely going to use 2 1/2" diameter cross bars, but will cut the side plates from 1/4" plate. I'd prefer 3/8, but I don't have any kicking around. I'm also on the fence about using a light bar because the only place to really mount it is above the lower bar and this will block too much of the grille. Again, this is something I'll figure out later.
The picture below is the short version I drew up.

[Lieferson]

Are you going to make a mounting tab for it to be bolted into the front of the bumper for extra support? all you would need is a rubber washer between the tab and the bumper to keep everything pretty and add some support

[hemi43]

Originally Posted by Lieferson

Are you going to make a mounting tab for it to be bolted into the front of the bumper for extra support? all you would need is a rubber washer between the tab and the bumper to keep everything pretty and add some support

Definitely !! I'll machine a urethane washer around 1 1/2 diameter about 1/4" thick so I don't mark up the bumper.

[Lieferson]

Originally Posted by hemi43

Definitely !! I'll machine a urethane washer around 1 1/2 diameter about 1/4" thick so I don't mark up the bumper.

Awesome, im excited to see the final product! hope i don't like it more than mine! haha

[hemi43]

I found a piece of 3/8 flat bar so I cut the sides out that. Much better than the 1/4" I was going use. The cross bars are 2" sched 40 pipe and are 28 7/16 long.
The push bar fits real nice and just takes a couple minutes to install and the bumper doesn't need to be removed. I ended up adding an extra bolt in the frame area because I'm not going to use a front tab that gets bolted on with the top bumper bolt because I really don't plan on pushing anything with it.
All that's left to do is sandblasting and powder coating.
If anyone wants a .DXF file of the side plates, PM me an e-mail that I can send it to. I'll send both the tall and short version I drew up.

[hemi43]

Got the bar welded today, and I was able to blast it before the rain came. I powder coated it tonight and decided to go with a fine textured black. Hopefully get it installed tomorrow.

[DeadheadNM]

What's next? 3D print the crossmember supports for a Hickey roof rack?

[robs71k5]

Does anyone know if this was a dealer product or perhaps a Hickey offering ? I haven't. Been able to dig up anything that resembles period correct documentation. But I can surely recall seeing these on trucks in that he earlier years

[jaros44sr]

Nice work, Hemi

[hemi43]

Originally Posted by jaros44sr

Nice work, Hemi

Thanks Jim !!

[hemi43]

Got the bar all installed today. Even with just 4 mounting bolts on the frame rail, it is very sturdy. If this bar was actually going to be used to push Fords out of the way, then I would use a welded tab which would utilize the upper bumper bolt and make it even sturdier. As I said before, if anyone wants a copy of the file, let me know. It would be cool to see it on other Blazers/Jimmys.
Dan