Denver Offroad and BHAF Install Day!
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Joined: May 2002
Posts: 6,522
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From: Sandy, Utah
Denver Offroad and BHAF Install Day!
Well, after many months of patiently waiting, my Denver Offroad front winch bumper (DOR) was delivered Friday right before I had to go to work.
Got to work, and my BHAF heatshield was finished
(had a guy at work who works well with metals fab me up one).
Started the install this morning at 9:30am, and minus a 30 minute jaunt to the hardware store (details later in thread) was finished at 1:30pm.
This story started way back on February 27th when I, having shown an interest in the DOR, was PM'd by Commatoze saying Layne, of DOR (in fact, he IS DOR) had a spare black bumper lying around.
I gave him a call, but the bumper was sold, so I bit the bullet and placed an order.
I'd heard of long waits for these bumpers, but always the wait was worth it,
as the bumpers are all hand made by Layne, no assembly line, just him, his welder, and the local powdercoating establishment.
The bumper was finished and ready for pickup or shipment back on June 6th, I was leaving for a weekend of camping the next day, otherwise I would have driven the 5 hours to pick it up personally.
He usually packs them up in a crate and ships them for a price of $150.00 (crates are expensive), but he has a guy that drives from Provo Utah (just south of Sandy where I live) to Grand Junction (DOR is located in Fruita, a suburb) once or twice a week, that would deliver it for $50.00.
As luck would have it, he had just left there when the powdercoating place called Layne to say the batch of bumpers was done.
And, the delivery guy was going to be on vacation "for a week or 2" after that.
Long story short, the bumper was picked up around Midnight Monday night (6/30), but a very busy week awaited him when he got back to Provo.
We connected Thursday, and he brought it up after the parade on the 4th, Friday.
I had planned on taking a lot more pictures, but I just plain forgot to, below is what I did take.
Here is my factory tinfoil bumper after removal.
I highly recommend an air ratchet, there isn't any room under there for a standard ratchet to move.
A set of large deep metric sockets is also recommended.
I used a 15mm, 16mm, 17mm and 19mm on various nuts and bolts.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0128.JPG[/img]
I had to remove the air dam just to be able to move the wrench around.
(uses torx screws, can't remember the size and one plastic "pop rivet" on each end)
3 bolts on each frame mount, and one side bracket and it just comes right out.
I then took the DOR mounting brackets and mounted them to the outside of the frame.
Brackets are 1/2 inch thick, quite heavy, and use 4 large bolts to connect to the frame.
Forgot to take pics of them but you can see them in Tom Goldens TDR gallery here-
http://www.turbodieselregister.com/u...45&width=2
(hope you don't mind Tom
he has great install pics as well)
I highly suggest not leaving them sitting in the sun while you remove the bumper, they get too hot to touch, let alone hold in place while starting the bolts.
If the brackets got that hot, imagine what the bumper will do.
Due to this, I decided to take the install into the garage.
My truck does not fit, but with a little greasing, I was able to slide the front end in, barely, just to have a little shade.
Here is a pic of the bumper installed, and the tight squeeze into the garage.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0131.JPG[/img]
(the blanket is there to block a huge sun flare coming off the windshield).
The frosty beverage is one of 8 I drank during the whole install, plus some ice water and orange juice.
Decided against beer, wanted my reflexes razor sharp.
The bumper isn't as heavy as it looks.
It is made from aircraft grade aluminum, then powdercoated black
(check with Layne for other options on color).
According to Layne, they have withstood many encounters with deer with nary a scratch.
It is a chore to lift it, but nothing near what a comparable steel bumper would be.
I was able to complete the install by myself.
The brackets make a nice shelf to rest the bumper on while you align the bolt holes, just a little shoulder lift till you slide the bolts in.
Can't really see it in the picture, but on each side of the winch mount there is a bracket with 3 15/16's holes you can hang some heavy duty D-shackles from.
Great to hook a tow rope on, a ****** block, or use as a Hi-Lift connection to jack the front end up.
Due to the DOR not hanging down as far as the OEM bumper, you have to trim the inner fender liners about 6 inches.
If you don't, the wind will push them against the tires and shred them.
I used a small saw, and got a pretty straight line.
I'll have to use the dremel to shape them a little better, get rid of the jagged edges.
Here is a side view, after I greased up and slid out of the garage.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0138.JPG[/img]
Now I just have to save some pennies and get the Warn 12000 winch.
Sad thing, I'll have to remove the bumper to install the winch.
BHAF install coming next.
phox
Got to work, and my BHAF heatshield was finished
(had a guy at work who works well with metals fab me up one).
Started the install this morning at 9:30am, and minus a 30 minute jaunt to the hardware store (details later in thread) was finished at 1:30pm.
This story started way back on February 27th when I, having shown an interest in the DOR, was PM'd by Commatoze saying Layne, of DOR (in fact, he IS DOR) had a spare black bumper lying around.
I gave him a call, but the bumper was sold, so I bit the bullet and placed an order.
I'd heard of long waits for these bumpers, but always the wait was worth it,
as the bumpers are all hand made by Layne, no assembly line, just him, his welder, and the local powdercoating establishment.
The bumper was finished and ready for pickup or shipment back on June 6th, I was leaving for a weekend of camping the next day, otherwise I would have driven the 5 hours to pick it up personally.
He usually packs them up in a crate and ships them for a price of $150.00 (crates are expensive), but he has a guy that drives from Provo Utah (just south of Sandy where I live) to Grand Junction (DOR is located in Fruita, a suburb) once or twice a week, that would deliver it for $50.00.
As luck would have it, he had just left there when the powdercoating place called Layne to say the batch of bumpers was done.
And, the delivery guy was going to be on vacation "for a week or 2" after that.
Long story short, the bumper was picked up around Midnight Monday night (6/30), but a very busy week awaited him when he got back to Provo.
We connected Thursday, and he brought it up after the parade on the 4th, Friday.
I had planned on taking a lot more pictures, but I just plain forgot to, below is what I did take.
Here is my factory tinfoil bumper after removal.
I highly recommend an air ratchet, there isn't any room under there for a standard ratchet to move.
A set of large deep metric sockets is also recommended.
I used a 15mm, 16mm, 17mm and 19mm on various nuts and bolts.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0128.JPG[/img]
I had to remove the air dam just to be able to move the wrench around.
(uses torx screws, can't remember the size and one plastic "pop rivet" on each end)
3 bolts on each frame mount, and one side bracket and it just comes right out.
I then took the DOR mounting brackets and mounted them to the outside of the frame.
Brackets are 1/2 inch thick, quite heavy, and use 4 large bolts to connect to the frame.
Forgot to take pics of them but you can see them in Tom Goldens TDR gallery here-
http://www.turbodieselregister.com/u...45&width=2
(hope you don't mind Tom
he has great install pics as well)I highly suggest not leaving them sitting in the sun while you remove the bumper, they get too hot to touch, let alone hold in place while starting the bolts.
If the brackets got that hot, imagine what the bumper will do.
Due to this, I decided to take the install into the garage.
My truck does not fit, but with a little greasing, I was able to slide the front end in, barely, just to have a little shade.
Here is a pic of the bumper installed, and the tight squeeze into the garage.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0131.JPG[/img]
(the blanket is there to block a huge sun flare coming off the windshield).
The frosty beverage is one of 8 I drank during the whole install, plus some ice water and orange juice.
Decided against beer, wanted my reflexes razor sharp.
The bumper isn't as heavy as it looks.
It is made from aircraft grade aluminum, then powdercoated black
(check with Layne for other options on color).
According to Layne, they have withstood many encounters with deer with nary a scratch.
It is a chore to lift it, but nothing near what a comparable steel bumper would be.
I was able to complete the install by myself.
The brackets make a nice shelf to rest the bumper on while you align the bolt holes, just a little shoulder lift till you slide the bolts in.
Can't really see it in the picture, but on each side of the winch mount there is a bracket with 3 15/16's holes you can hang some heavy duty D-shackles from.
Great to hook a tow rope on, a ****** block, or use as a Hi-Lift connection to jack the front end up.
Due to the DOR not hanging down as far as the OEM bumper, you have to trim the inner fender liners about 6 inches.
If you don't, the wind will push them against the tires and shred them.
I used a small saw, and got a pretty straight line.
I'll have to use the dremel to shape them a little better, get rid of the jagged edges.
Here is a side view, after I greased up and slid out of the garage.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0138.JPG[/img]
Now I just have to save some pennies and get the Warn 12000 winch.
Sad thing, I'll have to remove the bumper to install the winch.
BHAF install coming next.
phox
Thread Starter
Administrator
Joined: May 2002
Posts: 6,522
Likes: 4
From: Sandy, Utah
Re:Denver Offroad and BHAF Install Day!
Here is the promised BHAF install with pics.
I bought the BHAF last month while I was at Cummins getting fuel filters.
I had wanted the Fleetguard AH19004, the Marine version of the BHAF, due to it having wire mesh on the inside and outside of the filter, but they didn't have one in stock so I got their last AH19037, the standard BHAF.
$43.04 plus tax.
I printed out the template for the heatshield and asked a guy at work, who's handy with metalwork, if he would fab me up one in his spare time.
$45.00, he didn't have any scrap and had to buy the aluminum.
Called Outerwears Racing and ordered a water resistant prefilter, part number WR3325-105BL (blue), it is a stocked part due to the popularity of the Fleetguard BHAF, not a custom one as I was thinking.
$31.92 shipped to my door.
Two 5-7 inch hose clamps from Home Depot, the biggest they had,
probably could have gone with a 5-7inch and a 3-5inch.
$3.35
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0132.JPG[/img]
Wondering how to attach the heat shield where the factory airbox was, I had an epiphany.
Why not use the original hardware?
Took out the rubber grommets and torx nuts out of the factory box and measured the holes they came out of, exactly 3/4".
Only hole saw I have is a 1", truck is incapacitated, so I hop on the motorcycle and head to Home Depot to get a 3/4" hole saw.
A lot of guesswork, eyeballing and pilot holes to get the holes to line up correctly.
Of course, one was right under the edge of one bracket.
Here's a closer shot of the heatshield with the holes.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0133.JPG[/img]
Stick the rubber grommet thingys in the holes, hoping they still line up, and into the engine compartment it goes.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0134.JPG[/img]
A lot of wrestling to get the intake hose to go on both the turbo and the BHAF at the same time, tighten them both down and attach the BHAF to the brackets on the heatshield with the 2 hose clamps.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0136.JPG[/img]
<edit> The two mounts for the tie downs are mounted backwards, they guy that made my shield didn't understand how they went.
Intead of being "back to back" they need to be facing each other.
The way they are now, the filter sits on them instead of lying flat on the heatshield, might dent the filter if I hit a big bump or something.
He riveted them on, so someday I'll have to drill out the rivets and turn the mounts around.
Done.
Next year I'll get some more fuel flowing to take advantage of all that extra air.
I think I'm done BOMBing for a little while.
(above pictures are sized down, full size ones are located in my album, page 20 of Members Photos)
phox
I bought the BHAF last month while I was at Cummins getting fuel filters.
I had wanted the Fleetguard AH19004, the Marine version of the BHAF, due to it having wire mesh on the inside and outside of the filter, but they didn't have one in stock so I got their last AH19037, the standard BHAF.
$43.04 plus tax.
I printed out the template for the heatshield and asked a guy at work, who's handy with metalwork, if he would fab me up one in his spare time.
$45.00, he didn't have any scrap and had to buy the aluminum.
Called Outerwears Racing and ordered a water resistant prefilter, part number WR3325-105BL (blue), it is a stocked part due to the popularity of the Fleetguard BHAF, not a custom one as I was thinking.
$31.92 shipped to my door.
Two 5-7 inch hose clamps from Home Depot, the biggest they had,
probably could have gone with a 5-7inch and a 3-5inch.
$3.35
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0132.JPG[/img]
Wondering how to attach the heat shield where the factory airbox was, I had an epiphany.
Why not use the original hardware?
Took out the rubber grommets and torx nuts out of the factory box and measured the holes they came out of, exactly 3/4".
Only hole saw I have is a 1", truck is incapacitated, so I hop on the motorcycle and head to Home Depot to get a 3/4" hole saw.
A lot of guesswork, eyeballing and pilot holes to get the holes to line up correctly.
Of course, one was right under the edge of one bracket.
Here's a closer shot of the heatshield with the holes.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0133.JPG[/img]
Stick the rubber grommet thingys in the holes, hoping they still line up, and into the engine compartment it goes.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0134.JPG[/img]
A lot of wrestling to get the intake hose to go on both the turbo and the BHAF at the same time, tighten them both down and attach the BHAF to the brackets on the heatshield with the 2 hose clamps.
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0136.JPG[/img]
<edit> The two mounts for the tie downs are mounted backwards, they guy that made my shield didn't understand how they went.
Intead of being "back to back" they need to be facing each other.
The way they are now, the filter sits on them instead of lying flat on the heatshield, might dent the filter if I hit a big bump or something.
He riveted them on, so someday I'll have to drill out the rivets and turn the mounts around.
Done.
Next year I'll get some more fuel flowing to take advantage of all that extra air.
I think I'm done BOMBing for a little while.
(above pictures are sized down, full size ones are located in my album, page 20 of Members Photos)
phox
Registered User
Joined: Nov 2001
Posts: 389
Likes: 0
From: Heber, Utah
Re:Denver Offroad and BHAF Install Day!
Phox...As always you do good work on your truck. I do like the bumper, and I'll have to stay away from you if you ever want to play "chicken". You'll destroy my front end.. 
<br><br>Steve
<br><br>Steve
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Joined: Aug 2001
Posts: 566
Likes: 0
From: Omaha, NE
Re:Denver Offroad and BHAF Install Day!
Nice writeups.........<br><br>As much as I hate to say it, I was sitting here thinking, man that would suck if he couldn't get his truck backed out with the new bumper installed.............it looks like a very tight squeeze!
Thread Starter
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Joined: May 2002
Posts: 6,522
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From: Sandy, Utah
Re:Denver Offroad and BHAF Install Day!
[quote author=KatDiesel link=board=7;threadid=16737;start=0#157116 date=1057509355]<br>Nice writeups.........<br><br>As much as I hate to say it, I was sitting here thinking, man that would suck if he couldn't get his truck backed out with the new bumper installed.............it looks like a very tight squeeze! <br>[/quote]<br><br>That's the first thing I checked before I started bolting it on.<br>I set it on the brackets then did a walk around to make sure it didn't stick out further than the tires.<br><br><br>phox
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Joined: Jun 2003
Posts: 447
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From: Dallas Ft. Worth Metroplex, Texas
Re:Denver Offroad and BHAF Install Day!
Ha Ha I was wondering the same thing on whether or not it would be able to get out of the garage.<br><br>That is a nice bumper PHOX!!! Mine is similar but weighs probably 3 times more. Your top center tube is larger diameter(nice) and your headlight outline is a little larger(very nice).<br>Mine has expanded metal screen behind the center sections and my Catz lights mount high between the middle and upper bars.<br>I also had the 4X4 shop fabricate sleeves in mine for my factory fog lights.<br>Mine is AWESOME,, yours.... well I wish I knew where to get yours before I bought mine!!!! :
<br>James
<br>James
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Joined: Jun 2003
Posts: 447
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From: Dallas Ft. Worth Metroplex, Texas
Re:Denver Offroad and BHAF Install Day!
[quote author=JCL123 link=board=7;threadid=16737;start=0#157120 date=1057510208]<br> Catz lights mount high between the middle and upper bars.<br>[/quote]<br><br>I forgot too Mine has an additional bar across the middle...
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Thread Starter
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Joined: May 2002
Posts: 6,522
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From: Sandy, Utah
Re:Denver Offroad and BHAF Install Day!
Almost forgot one other little thing I ran into.<br><br>The bracket on the drivers side sits right up agains the tranny cooler line. I didn't have any rubber hose handy, so I wrapped it in about 8 layers of electricians tape.<br><br>I will check it periodically, and if it's showing problems I'll get some thick rubber hose and put around it.<br><br>Top View<br>[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0141.JPG[/img]<br><br>Down Under<br>[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0142.JPG[/img]<br><br><br>phox
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Joined: Feb 2002
Posts: 1,424
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From: Sturbridge, Taxachusetts
Re:Denver Offroad and BHAF Install Day!
Nice job, phox. Hey, what did you do about the front edge of the wheel well liners? The side pix doesn't show much in that area. Someday, I'll get mine. I ordered the clear coat finish, and he's taking forever to get to it.....Tom
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Joined: May 2002
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From: Sandy, Utah
Re:Denver Offroad and BHAF Install Day!
I just took a pencil and drew a line straight across from the bottom edge of the bumper to the inside edge of the liner and used a small saw and attempted to follow the line.
Missed it in a couple places, so I'm going to dremel it a bit to even it up and make it look a little less jagged.
In hindsight, I think I could have arc-ed the line down a bit more, starting even with the bumper, removing a little less material.
Passenger side
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0143.JPG[/img]
Drivers side
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0146.JPG[/img]
Originally, you wouldn't be able to see the frame from inside the wheel well, I removed 6-7 inches of liner.
phox
Missed it in a couple places, so I'm going to dremel it a bit to even it up and make it look a little less jagged.
In hindsight, I think I could have arc-ed the line down a bit more, starting even with the bumper, removing a little less material.
Passenger side
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0143.JPG[/img]
Drivers side
[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0146.JPG[/img]
Originally, you wouldn't be able to see the frame from inside the wheel well, I removed 6-7 inches of liner.
phox
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Joined: May 2002
Posts: 6,522
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From: Sandy, Utah
Re:Denver Offroad and BHAF Install Day!
Here's another shot showing the shackle mounts.<br>There are 3 on the drivers side, and 3 on the passenger side.<br>It is a 1/2 inch thick "L" bracket mounted with 3 large bolts.<br><br>[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0147.JPG[/img]<br><br>There are 2 offroad light mounts welded to the lower crossbar.<br>Also, plenty of room on the top or bottom of the bumper to mount more lights if wanted.<br><br>[img width=500 height=400]https://www.dieseltruckresource.com/yabbse/gallery/albums/userpics/IMG_0149.JPG[/img]<br><br><br>Once again, bigger pics in my Member Photos, page 20<br><br>phox
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Joined: May 2002
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From: Sandy, Utah
Re:Denver Offroad and BHAF Install Day!
Bumpin this back up.<br><br>Layne just called me to find out if I got it and if I had any installation problems or questions.<br><br>Talk about customer service 8) .<br><br>Asked him a couple things:<br><br>Where was his web site?<br>He said the Earthroamer guy was in charge of it for him, and he had fallen behind on the upkeep (paying for the domain I would think),<br>but he is now working with another guy to get it back up and running.<br><br>Why doesn't he put a "Made by" sticker or plate on the bumpers any more?<br>He didn't like the way they looked, and is in the process of coming up with a polished stainless plate, Laser cut plate for them, and will send me one when he gets them figured out.<br><br>Does he make rear bumpers?<br>Perhaps similiar to the one he made for Earthroamer?<br>He is still in the development stages on one smaller than the Earthroamer one, it had storage for a Hi-Lift, tow straps, and a winch.<br>The one he is currently trying out wouldn't have the winch integrated into it, but would retain the Hi-Lift and tow strap storage, with a lift top design, and have similar flow lines to the front bumpers.<br>He is also developing one that has a swing away spare tire and fuel can/water can carrier.<br>Not like the ones on currenty SUV's, but a double gate that swings out both sides, like a "barn door", so less to "walk around" when it is swung out.<br><br>I will be contacting him about the rear bumper in a year or so (when I can afford it ), I want one that matches the front, and since my spare won't fit under the bed anymore, the spare tire carrier option will really come in handy.<br><br>Hope this isn't cheerleading too much.<br><br><br>phox
), I want one that matches the front, and since my spare won't fit under the bed anymore, the spare tire carrier option will really come in handy.<br><br>Hope this isn't cheerleading too much.<br><br><br>phox
