Repairing front end damage done at the track last month.
I've got new sheet metal on the car now. I would like to replace the front OEM bumper substructure with something more formidable... and would like some design suggestions.
I had gotten some advice from Emilio. I believe he explained that he uses two small aluminum tubular "v's" that he bolts up under each side of the bumper cover. I was going to go with this design, but found that my core support was too damaged to repair. My design will have to replace the function of this core support; hang the intercooler and tie together the frame rails.
So far, I have cut the core support out and cut back the frame rails one inch, then welded a plate to box in the end of each frame rail. I think I will use this to mount a single continuous nerf bar; which will also tie together the frame rails.
One consideration is that I'd like the nerf bar to be sturdy enough to bump, but weak enough to deform (I want it to fail before the frame rails do). I am thinking that 1 1/2 .090 mild steel tubing; or perhaps .090 or even .060 high carbon steel.
Does anyone here have fabrication experience that might chime in?