I'm probably going to plate the top of it. Should I dimple die the plate or leave it solid? Or, should I use expanded steel rather than sheet?

 

Also, should I use 2 or 3 kickers supporting it from below? It's already strong enough for me (190lb) to bounce up and down on, but I'd rather it not break.

 

The ends are getting shortened a little, but I'd rather start too long and remove a little than have to weld extensions on.

 

One of my roommates teaches welding at the local Community College. I asked him if he would have any leftovers from a project he was working on that used a sheet of 16 gauge, he said no but he could grab some from school. I measured the bumper, and think I told him it was 44" x 4.5". I didn't specify thickness at all. I also asked if he could grab me a couple pieces of thicker material for where the kickers come down: if I just weld them straight to the bumper I'm afraid they'd just push through so I was going to add some plates to spread the load out. I asked for something on the order of 1/8" for them, and 3" squares. 

 

I got home today to find a couple 3" squares and a 5-6" x 49" piece. The squares looked perfect for an application like this, and appear to be 12 gauge (.1084"). However... the bigger piece is the same thickness. Sure, it'll work, and at 8lb it's at most 4lb heavier than what I would have used, but I'm not sure that I can dimple die it with the die that I can borrow. On the other hand, it seems like a pretty much perfect thickness for when I re-do the front bumper and have to make some new plates that bolt on where the OEM bumper does. 

 

spoob, I can't really complain about free material (I might pay him for it, but he's refused payment for similar things in the past) but I wish it was 14 or 16 gauge instead. If I do end up using the thick stuff for the top I guess I won't need a support in the middle, I guess that's an upside. 

Edited May 2, 201411 yr by Junkie

 

Mostly done, just need to trim/cap the ends and paint. Don't know why the pic is so dark, flash was on, but it hides the shitty welds. 

Forgot to mention, the dimple die seriously taco'd the plate. That lead to crappy fitup and ugly welds, so I did a half assed job of grinding them down. Oh well, it'll hold up.