JenKor

We were in need of a bumper extention on the back of our fifth wheel camper.  We had a fairly large Honda 6500 generator that was taking up a great deal of our truck bed.  The bumper extention was to serve two purposes.  The first was to hold our large generator.  The second was to add a receiver hitch to the back of the camper for future toys to be pulled. The main reason for the project was for installing generator on back of trailer.

1 ) Here is a picture of our camper prior to the bumper extention.

2 )  This is a side view of our camper prior to the bumper extention.

3 ) I started with a bumper from a flatbed pickup that was given to me.  It had two rails that were 3 1/2 inch tubing and each side was 8 feet long.  The tubing was removed from the bumper and one side was cut into two 4 foot pieces.  I was also given a receiver from a pickup that I cut the ends off and used for frame extentions and they were also used for something to hold the tubing in place while I welded it to the frame.  The tubing was a bit heavier than I would like but you can’t complain about free material.  In fact the tubing weighed 40 lbs for the 4 foot extentions and 80 lbs for the 8 foot section.

4 ) The first step on the camper was by cutting off the ends of the bumper that were past the frame, and attaching the ends of the reciever hitch on each side upsidedown.  This was to help in extending the area where I could weld the 4 foot pieces too and gave me something to help hold the tubing in place while I welded it to the frame.

5 ) I then took the two 4 foot pieces of tubing that had been removed from a flat bed and welded them to the frame.

6 ) With the 4 foot extentions in place, I was able to attach the 8 foot piece to the ends.  This made the new bumper. 

7 ) I then took some 2 foot pieces of angle iron to fill in the middle of the new and old bumber.  These pieces gave the center a bit of stabilization. 

8 ) Now was time to add the receiver hitch.  I took the remaining piece of the old hitch and centered it on the new 8 foot bumper.  I welded it to the bumper.

9 ) I ran a 8 x 3/4 inch bolt through the frame and tubing for a bit more strength in case the welds would ever break.

Below is a picture from the ground looking up at the bottom of the extention.

This is a side view of the camper bumper extention.

Here is a picture of how the tubing was attached to the frame.

10 ) I was not happy with how the ends were looking so I add the pieces of the old bumper that I had cut away to the ends and added a 2 foot piece of angle iron to the end to complete the extention on the ends.  Below is a picture from the side with the newly added pieces.

11 ) I was a bit concerned about how the new bumper was attached to the 4 foot extentions so I added a sqare piece from the extention to the new bumper.  I will show this later in the post.

Here is a picture from the back of the camper showing the receiver.

Here is the piece of square tubing that I welded on the extention and the new bumper to give it a bit more strength when something is attached to the back and being pulled.

Here is a picture of how I welded the ends of the old receiver hitch to the frame and to the 4 foot extentions.  This is looking from the top of the camper bumper extention and toward the camper on the passenger side.

12 ) Cut out a piece of 3/4 inch plywood to fit the top and screwed it to the frame.  Attached a few eye bolts to strap the generator down.  Also bolted a tool box to the back for extra storage.

Had problems getting out of the driveway so had to remove generator, tool box, and playwood.  Cut off the 8 foot bumper and flipped it upside down and welded it back on.  Now we can make it all the way out of the driveway without scrapping.  Should have tested this before putting on the plywood and generator.  Lesson learned.

Here is a picture of the drivers side with the tool box attached to the camper bumper extention.

Finished product.  One camper bumper extention DIY style.