60-66 Stepside rear step bumper modification

[WhippinSaw]

Finally warmed up enough to start working on the truck. Took the bumper off and straighten the rear sill plate and the diamond plate where it meets the sill. The diamond plate is still bent down some by the barden tag an I will fix that later. The floor jack worked good to get the bumper in position. A factory small hole on the frame lined up with the far slot in the bumper and I used a small bolt to tilt the bumper up and down to find the best angle. It went up about 3/4", and went towards the rear 1 1/2" and had tilted it down some. Just had to drill the small hole out bigger and drill a new hole for the other.Looks good so far, got nothing to lose so I'm ready to cut, If you could check some overall measurements, I can measure it twice and cut once, I got 66 1/4' under the rear sill and think that will be around 55 after Its cut and 76 5/8" overall not sure what that should be. Thanks murhy98

[murphy98]

Hey WhippinSaw,
the gap under the cross sill is looking really good after your adjustments. I just checked the two measurements you asked about on my bumper. I got 55 1/4" for the width of the vertical portion of the diamond plate under the cross sill, so just about what your measurement is. For the overall width of the bumper I get 73 5/8". Perhaps you can take a carpenters square and put the short leg along the rear edge of the bumper and have the longer leg just touching the rear fender but long enough to reach just short of the molded lip area of the fender see last photo in post #18 above for reference (maybe put some masking tape on the fender so the square does not scratch it) then draw a line on the top of the bumper to simulate the end of the bumper and repeat on the other side then measure the overall width of the bumper going by those two lines and see what that comes to before you do any cutting. Check that measurement against mine to see if you are close. Let me know if you need more info, happy to help!

[WhippinSaw]

Thanks for the carpenter square suggestion, I got a good look at it and noticed my fender with the spare tire cutout is narrower than the other. Never noticed that before, barely noticeable in the pic. That side will have a shorter bumper than the other. I have a metal super mart close by, looks like I need 2 pieces of 1/8" diamond plate steel 12" x 24" and 2 pieces of 1/4" X 4" flat stock steel 2 foot long before I start cutting. If you get a chance could you post a couple of rear close ups so I can better visualize that molded area like the pic below. Thanks murphy98

[3/4ton Randy]

This is a great thread guys! I will soon be starting on my own rear bumper on my longbed stepside. Your's turned out great.

[murphy98]

Originally Posted by 3/4ton Randy

This is a great thread guys! I will soon be starting on my own rear bumper on my longbed stepside. Your's turned out great.

Thanks 3/4ton Randy, good luck with your bumper, post some before and after pics when you are done.

[WhippinSaw]

Thanks murphy98, Yes that helps, still seems that I am to low, I cut off the diamond plate to 55 1/4 and am going to remount the bumper after I clean it up so I can lay some new diamond plate on the top of the bumper to see where it ends up on the fender. I want to cut it like yours under the diamond plate vertical riser like the picture below to rid a little more rust and smooth it out, I think thats on a straight line with the bed then too. I think its 3 inches, could you confirm when you get a chance.

[murphy98]

Checking my bumper measurement from the edge of the vertical diamond plate to the factory weld seam I get 2 3/4", the distance from the factory weld seam to the outer edge of the bumper is 12". The new diamond plate pieces I used to fill in the new section were exactly 12" x 24" which worked out perfectly for my bumper. Because your bumper was originally for a feetside, not sure if the factory weld seem would have been in the same location as the stepside version? Let me know if you need any more dimensions, your progress is coming along nicely!

[murphy98]

Originally Posted by WhippinSaw

Thanks for the carpenter square suggestion, I got a good look at it and noticed my fender with the spare tire cutout is narrower than the other. Never noticed that before, barely noticeable in the pic. That side will have a shorter bumper than the other. I have a metal super mart close by, looks like I need 2 pieces of 1/8" diamond plate steel 12" x 24" and 2 pieces of 1/4" X 4" flat stock steel 2 foot long before I start cutting. If you get a chance could you post a couple of rear close ups so I can better visualize that molded area like the pic below. Thanks murphy98

Here are some pics of the contoured tip of the bumper side rails where it meets the fender, hope these help? It's only about the last 2-2 1/2" of the bottom portion of the tip that is bent (sort of a compound curve top to bottom of the edge & horizontally a couple of inches from the end) to match the contour of the fender. I took the last pic from underneath so you can see how it bends in to fit the shape of the fender. The top edge is straight all the way. Bottom edge of the bumper side rail should be flush with the bottom of the fender. In other words you should not be able to see the bottom of the fender dropping below the bottom of the bumper side extension. Obviously, I did not have to deal with making these contoured tips as I was able to reuse my original tips however it may be helpful to use a scrap piece of thinner metal or tin to make up a sample of the tip before trying to shape the thicker steel piece.