Hi everyone,
Firstly, Happy New Year everyone, I hope you all had a great Christmas.
I’m long overdue on a build update, so this one will have a few photos of my efforts over the past few weeks.
As previously mentioned I decided to have a go at making an aluminium bumper. I wanted it to be light so I decided to make a hollow bumper based off Steffan’s plans. Using Visio I made up a template and started work.
Here are the side wallls based directly off the plans.
However, as I started working out the top plate I noted that the side wall plans don’t line up correctly with the reference bumper photos on this site. Specifically, around the underside of the centre where the section tapers down. I ended up building the missing part back up with weld and progressed to make the top plate and centre wing walls.
I welded these parts up and filed/sanded the edges out.
I made up the back plate in similar fashion to the top plate.
Did a test fit of the back plate.
Then weld on the back plate, welded up the ends and filed/sanded (and sanded some more) the edges back to finished the metal work.
Test fist against the pack shell.
While not perfect, I’m quite happy with how it turned out given my developing welding skills. The next step with it will be to use some epoxy filler on the inside edges to create the taper along the fins. This will be tomorrow’s task.
As a side note I found this to be the most difficult part to weld to date, but then again I think that I think that about each part somewhere along the line. Oh, and I’m still trying to find a good way to unclog aluminium from my files.
Anyway, I hope that you guys/gals found this update interesting. Until next time, bye.
Pete 
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151024_183325_zpstihsw9gz.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151025_165524_zpso9dvohwb.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151108_162400_zpsnyieqrt0.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_222901_zpsqwfomhqg.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_222922_zpsfgah4nkh.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_222932_zpsbr8ng53a.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_222950_zpsbaphcyw9.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_223024_zpstjnhgdtr.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151213_150935_zpswmiwnv5r.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2016-01-01%2021.43.46_zpsgvn1gkre.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2016-01-01%2021.46.25_zpsoyqsjyvb.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2016-01-01%2021.49.32_zpsi9vmhy0d.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2016-01-01%2021.51.02_zpsqqpavynq.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151230_155205_zpsz0wwle70.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_183200_zpsnrjimnvg.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_183046_zpsl56hwfuv.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_182649_zpsz3yblsag.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_182701_zpszeatnqcv.jpg.html){kind=link}
](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_183432_zpsvl2zoire.jpg.html){kind=link}