Evil off-road Abbadon front bumper

[BadNewsBronson]

Hey guys long time no post! Happy to say the abaddon came in! Going to use the guide @Jhollowell posted earlier this year! I’m excited but it’s also my first cut too. Wish me luck fellas lol

 

[BadNewsBronson]

What’s up gents! So quick update, the bumper is on and for my first cut I think it went reasonably well considering it was my first, but I did run into an issue when trying to adjust the driver side frame horn. I needed to put in a spacer so the bumper stuck out evenly. Not 100% sure why exactly it was uneven as I felt the cuts were pretty close to par. Followed @Jhollowell advice with the straight cut for one of the horns but but then tried a 2” cut down and then did the 45 cut. Both ways were ok I think. Overall it’s definitely way sturdier than stock and the next move is to put a 40” light bar in to fill out the gap..

Side note that first cut gave me hilarious anxiety since there was no turning back after that

 

[Irregular F150]

Looks great!

 

[BadNewsBronson]

@Irregular F150 thank ya bro!

 

[Latchkey Kid]

Installed the bumper yesterday and for the most part was pretty simple and straight forward. It was a learn as you go kind of thing for me so i'll share some of my learnings. First off i there are really no instructions on where to cut the frame and it does use the existing hole so be carful not to cut too much off. 4.5" from the back part of the horn seemed to work out for me. The angle cut was a little difficult so i made a straight cut first then held up the new horn and scribed a line and made my cut. I started with an electric grinder for the first cut and that's a bit unwieldy especially sitting and kneeling under the truck. Maybe jacking it up a little would have helped and definitely a lift would be ideal but i did it just sitting on the tires. I used the grinder for the passenger side and it worked out, but the drivers side i decided to use a reciprocating saw with a long blade to make my first cut all the way through. That went way faster and was much more manageable and had the advantage of not throwing sparks everywhere. It also gave me a pretty even cut straight down. For the angle cut i used a cordless grinder and that worked really well too. its a little slower but didn't throw as many sparks and was a little easier to manage. After the cuts i cleaned them up with a flapper wheel and hit them with some primer. The one issue i had and Ken mentioned it in my previous post, is the horn is held on with one through bolt so on some frames it will rock, even when tightened. I happen to have a lathe in my garage and happened to have some stainless tube so i made 2 sleeves to go between the frame flanges so when you tighten the bolt, it doesn't deform the frame. After bolting everything up i had no rocking and the bumper looks great and feels solid. Really happy with the way it turned out and how it looks.

Hardware. Power coated the bumper bolts to blend in with the horn.
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new frame horns. Beautiful tig welds
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Passenger side first cut
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Little tough to get a straight cut with the grinder. Not a big deal since the horn covers it.
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This is hugely helpful. Ordered my Evil imper and mirrors today!!