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Kenodog · Joined: 25 Jun 2003 Posts: 2669 Location: Vancouver,B.C.

I am thinking about making some aluminum bumper brackets for my car.These would replace the Boge shocks.They will hold the bumper the same distance out as a drilled and compressed Boge.However they will also be lighter by about 4-5 lbs. each.Times 4 per car and there goes 16-20 lbs! Anyway the first set I will fab up myself but if anyone else wants some a friend of mine works in a shearing/forming shop and suggested to make some to sell.So is anyone interested? A set of four (front&rear) with shipping will be about $35-40.Is it worth it?
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1979 Euro 931, Olive
1981 931, Sabine
1991 Ford Ranger XLT 4x4, Ricky
1996 Ford E-350 ex-FedEx Van
2014 Mazda CX-5 (Kinderwagon)
2019 KTM 790 Adventure
2024 KLX300
2024 KLX140

Lizard · Posted: Fri Dec 19, 2003 8:32 am Post subject:

count me in
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3 928s,

Chrenan · Joined: 15 Jan 2003 Posts: 3903 Location: Canada

Count me in...
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1987 951 - M193 Version for Japan

924RACR · Posted: Fri Dec 19, 2003 11:50 pm Post subject:

Those would seem to be a natural pairing with fiberglass bumpers for racing applications. Perhaps selling them to a retailer would be wise, to improve distribution and volumes? I'd be interested for one of my 931's, but what a PITA to get them over the border, right?

For example:
http://www.fiberwerks.com/
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Neil924 · Joined: 18 Mar 2003 Posts: 4225 Location: Canada

If they were made in canada thenn it should be easy. If they were ... say made in Germany and were from the factory then you would pay more.

Lizard · Posted: Sat Dec 20, 2003 1:32 am Post subject:

924Racer, actually shipping across the border is no biggy, you label it as a gift no taxes payed, he isn't really pulling profet so it isn't that bad, or he doesn't have a company name for his parts, so it would just be shipped say as a "christmas" gift
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3 928s,

Kenodog · Joined: 25 Jun 2003 Posts: 2669 Location: Vancouver,B.C.

Don't worry about shipping.Lizard is right.I've shipped a ton of stuff to the US using the gift clause and have never had a problem.When I get the first set made I will post pics so you can see what they look like.The aluminum i'll be using is thick enough that i'm not worried about failures.They will be direct bolt on units.Take maybe 10 mins. to do both bumpers.
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1979 Euro 931, Olive
1981 931, Sabine
1991 Ford Ranger XLT 4x4, Ricky
1996 Ford E-350 ex-FedEx Van
2014 Mazda CX-5 (Kinderwagon)
2019 KTM 790 Adventure
2024 KLX300
2024 KLX140

924RACR · Posted: Sat Dec 20, 2003 3:03 am Post subject:

OK, then, keep me posted!
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

CBass · Joined: 03 Nov 2002 Posts: 2807 Location: Vancouver, Canada

Don't forget to take metal stretch into consideration when bending the brackets.
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'81 931 in various states of assembly

welder · Joined: 16 May 2003 Posts: 158 Location: cumberland,maine

Kendog is right, being a welder and machinist by trade these would be very straight forward to build and install. Be aware that without the shocks your bumper won't stand much of an impact without cracking or completly breaking. Although it can also be easly tig welded. When making the new aluminum shock replacements it will most likley be necessary to weld new brakets where the shock meets the bumper cause if you've ever seen this attachment point it's kinda weak and surprisingly flimsy
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I have a 78 n\a currently under restoration.

Kenodog · Joined: 25 Jun 2003 Posts: 2669 Location: Vancouver,B.C.

O.K.,here are the materials I have to make the first set.If you have the luxury to be holding a Boge in your hand you will understand this. The "U" shaped piece on the end will be identical in size and shape except out of aluminum.The shaft,so to speak is a piece of 1 1/2" square aluminum billet.And for the vertical backing plate I have some 3/8" cold rolled plate.The reason I think aluminum will work as well as steel in the application is because the bumper will be sitting only half the distance away from it's mounting point vs.the stock set up.This means that if you calculate the leverage force applied,it is a much easier load
beingcloser to the solid mounting point.If we have a physisit or an engineer on board please do the math.And like I say,mine will be the testing ground,if i'm not happy with the results I won't sell them.
L,[/b]
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1979 Euro 931, Olive
1981 931, Sabine
1991 Ford Ranger XLT 4x4, Ricky
1996 Ford E-350 ex-FedEx Van
2014 Mazda CX-5 (Kinderwagon)
2019 KTM 790 Adventure
2024 KLX300
2024 KLX140

welder · Joined: 16 May 2003 Posts: 158 Location: cumberland,maine

Kenodog, your materials sound plenty strong, also I like the idea of being different in length to change the front and rear profile. The weak point I spoke of is where that "U" shaped piece attaches to the bumper, actually part of a weakly fabricated bracket inside and tacked to the bumper. Your replacement will be plenty rugged. Have you ever noticed that when removing all the paint from the bumper before painting exposes numerous spider cracks. If you look inside the bumper you'll see the cracks go completly through the casting. These can be welded up quite easly. These tend to occur when minor impact exceeds the max 5 mph limit for the shock or they are worn out
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I have a 78 n\a currently under restoration.

924RACR · Posted: Sun Dec 21, 2003 1:56 am Post subject:

Oh, crap, I'm sorry, I didn't realize you meant to use the compressed length of the shocks. I need standard length brackets, will be mounting a fiberglass bumper. Ah well, it's not a priority anyway...
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Mikri184 · Joined: 12 Sep 2003 Posts: 746 Location: Ferndale, WA

I would be interested in getting a set for my car but want to see a finished product first, so get your car done so you can bring it down

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Life is to short to be looking for something?

AndyFranklin · Joined: 07 Oct 2003 Posts: 184 Location: Novelty OH

Vaughn,

I'm in the process of fabbing some "imitation" bumpers - similar AN mounts (in concept, at least), 1x3 AN bar, and fiberglass skin. For mine I am planning on shortening them, but making "full length" would be easy.

Of course, I'm not sure I would actually want to use them....

I've been wrong on my IT rules, but I thought you were required to use the stock bumpers. There is no provision for alternate materials. Unless you want to lose the 400 pounds and come play in FProd.