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1992 up frame modifications for front bumper with skid plate
When you remove the front bumper to start building an offroad type front bumper with
maximum ground clearance in mind, the frame stares at you with all its ugly impact ripples
that Ford decided to incorporate into their front ends. On earlier trucks we simply angle
cut the frame, drilled some holes and our main tube mounting brackets were done! Not so
with 92 and newer frames. Here is what they look like.
 
What we are trying to accomplish here is to create a completely bolt on front bumper
and skid plate designed for maximum ground clearance! Why not weld it on? It certainly
would be easier. Because when you have to work on your truck it is nice to be able to
remove it , also if you crash it , repairing or replacing it is by far easier. The
following photo is the complete front bumper with light tabs and skid plate mounts ready
to bolt on. 10 bolts total hold the complete assembly to the frame when completed
properly.
The front bar ready to fully welded and ready to install. The next picture is the
bumper flipped over with the skid plate. We fabricate the skid plate from 3/16 aluminum,
countersink mounting holes for flat Allen head stainless hardware. The finished product
looks clean and sanitary.
OK lets get to the frame modifications. The first photo shows cutting the angle
bracket off and the second picture indicates removal of the sway bar mount. Which by the
way I never run the factory sway bars as they are in the way for the most part and by
design cannot take wheel travel very well.
Next we will layout and cut the frame on the angle we need. Use the mounting bracket
and line up with the body mount to get the idea. We used a plasma cutter here but a torch
will work as well. You can use a cutting wheel as well but it takes longer. Watch cutting
where the frame overlaps it is two layers thick and will certainly cut different.
 
After cutting and prep work is complete your frame horns should look like this
 
This shows the new frame horn bracket ready to locate to the frame horns. Driver side
bracket showing detail of weld nuts etc. The bracket on the left bottom is the junction of
the lower crossmember and the return of the main front bar of the bumper assembly. This
will be on the bottom of the frame horns after installation is complete.
The following pictures show the new frame horns installed, note the spot welds on the
inside of each frame end. Final welding is completed on the vehicle, including sanding and
prep for paint.
 
And now you are ready to bolt the bumper and crossmember brackets on and complete the
fitting and welding necessary to finish push bar. The following photos show completion and
final appearance.
 
And the final product after a lot of work! Also check out the front fenders, you know
Ford did not make those jewels. It is hard to see but there is a 16" travel kit on
the front of this truck . A super lift came out because of frame and handling problems and
ours went in. Ryan is extremely pleased with the performance and looks of his truck now!
 
This concludes our feature "frame horn mods on new fords" , please let us
know what you think. Thank You!
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- Telephone
- 619-562-1740
- FAX
- 619-562-6151
- Postal address
- 10996 NORTH WOODSIDE AVE.SANTEE,CA. 92071
- E-mail
- General Information: john@autofab.com
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