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1989 W550 (Build Thread)

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Old Nov 19, 2025 | 03:54 PM
  #151  
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Not far off from the 3D design I did a few years ago. Definitely needs the side steps and front flares to tie everything together. A little empty below the doors at the moment.




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Old Nov 23, 2025 | 04:30 PM
  #152  
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One side almost done, just need to make the cover.


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Old Dec 7, 2025 | 05:57 PM
  #153  
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Mocking up the front bumper. Going to stick out like clown shoes, until the fender flares tie it in. Wanted it big, so that I have a platform to work on the engine with. A little bit of changes needed, to refine it.




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Old Dec 9, 2025 | 09:17 PM
  #154  
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Finalized the design and drew the parts up in CAD. Sent to a shop near by to have the pieces cut out of 3/16”. Should be ready next week, so that I can start putting the bumper together next weekend.
Bumper may inspire me to make the fibreglass flares next.



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Old Dec 10, 2025 | 09:29 AM
  #155  
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I will be watching your fiberglass fender work.
Truck is looking great.

When I use CAD…it stands for Cardboard Assisted Design.
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Old Dec 10, 2025 | 02:21 PM
  #156  
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Haha! I’m very familiar with such CAD. I was going to use cardboard cad, but had some thin sheets of wood laying around. So, WAD?
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Old Dec 10, 2025 | 04:49 PM
  #157  
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I had to zoom in yesterday to make sure I was not seeing things. I chuckled when I saw the wood grain.
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Old Dec 14, 2025 | 08:00 PM
  #158  
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Unfortunately, will not be able to use a stock grill, in any way, non intercooled, or intercooled. Will have to make a custom grill, so figure I may as well do something fun with the headlights. Quad lights anyone?



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Old Dec 15, 2025 | 06:21 AM
  #159  
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Nice look, just like the ‘79’s

Same way I installed my round head light bucket in my 2wd Ramcharger build using a ‘90 core support. I ended up mounting them over cut outs I made in the core support, rather than trying to weld them in flush and hope the placement was spot on when I put the grille over it. This gave me more wiggle room to adjust placement during assembly.
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Old Dec 15, 2025 | 04:54 PM
  #160  
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Had a little time to tack the right side together.


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Old Dec 17, 2025 | 08:45 PM
  #161  
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Little more progress.

Main middle bottom section that bolts to the frame is 1/2” 6x4 angle, that will mount a winch down the road. The outer sections are 3/16” bolt on pieces, along side the middle top section, that can also be removed. Making it modular, so that removing the bumper, if need be, will be a one man job.

Once it is all bolted together and straight, I’ll start working on the fender flares, since the bumper now makes the truck look a little goofy.




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Old Dec 17, 2025 | 10:20 PM
  #162  
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You are definitely a master fabricator, but aren't you worried about showing up on a job with this and spending several hours going over your build? Again, what a great build. Do you have a plan for paint yet?
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Old Dec 17, 2025 | 11:16 PM
  #163  
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Thanks man!

Not sure about the master part, but I do take some pride in being able to do an above average job, with below average tools! Dream of the day I have my own shop set up with a few items that could help me do a little higher quality fabrication. Ei. a mill, lathe, brake and roller. Maybe even learn to tig aluminum and stainless along the way.

Haha, well most of the people that would care to know more, probably know how to fix their own stuff, so may not be too much of problem. Am hoping it stands out enough to be a bit of a rolling business card though.

Will do a two tone flat black and gloss gunmetal
grey. This is my old first gen from 15 years ago, which is the inspiration for colour.

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Old Dec 18, 2025 | 02:28 AM
  #164  
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Looking great! Great skills in making your vision come to life.
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Old Dec 26, 2025 | 03:23 PM
  #165  
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Not entirely sure yet how I feel about it. Will trim the lip up about an inch all around.






Edit showing trimmed, looks a bit better.


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