Hi, everyone. Like the subject line states, I don't know entirely who to talk to, but I've done some very preliminary work here and reached out to one entity, which ended up being a dead-end. I'll try to lay this out suscinctly.

Premise: Our 2nd gen front bumpers, when new/perfect, are a pretty handsome design, and the material change from chrome to the lower grey plastic trim piece creates a nice style line that aligns with the break in the headlight and corner light on each side.

Problem: When said bumpers are now 20 to nearly 30 years old, worn out, faded, or banged up, we rely on the aftermarket to help us out. And as we know, "direct replacement" parts are not always so. This goes especially for the front bumper. Tales of woe ensue. Replacement black top caps with vertically-misaligned mounting clips, misaligned holes on the air dam, and who knows what with the lower grey trim (which is already standing off the chrome bumper due to broken clips or a top cab that doesn't/can't retain the grey plastic's "wings" due to mounting clip error).

Solution: Not putting a 4th gen HD bumper on it (TONS of work, with an honestly incongruous look), even if that idea of "more chrome" is a good one, IMO. Humor aside, what I'm thinking here is to have the entire lower/main bumper in chrome, with the "skin" or surface of the lower grey plastic being part of that form. [without the grey trim, the bumper is recessed/set back--I don't want that] Have it chrome but keep that "style line" as I believe it to be integral to the aesthetic of the front end. This would do 3 things: 1) match the rear bumper: black plastic top cap + chrome lower/main 2) reduce complexity in appearance but really in assembly/disassembly 3) make the black top cap free to not have to try and retain the lower grey trim piece, which contributes to a subpar look.

My issues: 1) Access to CAD files (short of me somehow scanning the thing and recreating it) 2) access to manufacturing 3) Knowing who in the world do I talk to if I wanted to make it happen

I realize this is chasing after the wind here, that is, trying to make a 25 year old truck (in my case) not look like I don't care about it. But I don't like an aggressive bumper offering. Those are fine for those who want or need it, but for us that are working to keep things stock or nearly so ("OEM+"), a bumper solution that is OEM-derived could really be something and I think it has merit. This belief has only grown when I took this idea from bouncing around my head to Photoshop. These images are a 'first pass' and things would be refined (like all design work is), but I think you will all get the idea pretty clearly.

So I'll leave you with some comparative photos and ask for any input or ideas as to who in the world I could talk to about this? I am not a vendor, presently have no plans to become one (or fabulously wealthy, lol), nor is this a "tech" question--really trying to play by the rules here and would greatly appreciate any help, even if it's simply "I like this idea; I'd buy one." Thank you in advance, truly!!

Side view, stock:



Side view, Photoshopped all-chrome bumper:



Front three-quarter view, stock:



Front three-quarter view, Photoshopped all-chrome bumper:

 

You would have to remove the texture and make it smooth then use this product.

 

I like that idea for current bumper+grey trim setup, but that will only work if the grey trim piece is behaving and cooperating with the black bumper cap. To reiterate: I am wanting to move away from that--away from the fidgeting (installation etc), the effort to make look like it should, and away from a busy visual composition.

 

It's been a few weeks, but there is a second run at this I will be taking very soon. Stay tuned, or don't. Hoping that it will lead to more developments on our trucks-as-testbeds, but we will see.

 

Still not exactly sure what you are trying to achieve. But it sounds like you want a solid metal bumper. You would have to fabricate(cut up another front bumper) the metal weld it on then get it chromed or use the process i showed in the other post. I have not heard of any issues with the replacement bumper parts like what lmc sells but it's possible.

 

I figured I should have done a cross-sectional view, even with the visuals (Photoshop images) provided. So here it is (below). Somehow I've mentioned this everywhere else / to everyone else but here. The manufacturing of this would be a stamped steel piece which would then be chromed. I could go the personal one-off fab route (which was an initial consideration), but this whole endeavor is meant to be an aftermarket-type "OE replacement" available for anyone to buy--in that it's direct fit, OE quality, OE thickness, but of a slightly different-yet-OE-looking design. It's another option in addition to strictly stock/OE replacement bumpers, 4th gen bumper conversions, etc out there; its primary goal is to provide a cleaner front look via providing more (clean-surface) exposed chrome as well as lessen the complexity that the original Dodge design presents. Again, the Photoshopped images above show how it would look, and the diagram/cutaway/cross-section/whatever below shows a before/current and after/proposed alteration. As to who could manufacture it (stamping tooling and setup is $$$) and talking to them about this, I don't know yet, and it's a phenomenally tall order as I am just one random guy (and a random guy on the internet at that) with only a design and CAD files (soon) to offer, and maybe a couple bucks. So this could be something, or it could be one of a billion Interesting Ideas With Good Intent (TM) that go absolutely nowhere.

Upper cross-section shows current Dodge design with the chrome portion of the bumper "bumping out" to be essentially flush with the black and grey plastic trim.

Lower cross-section shows my updated design where the lower grey plastic trim piece is done away with. The chrome portion does not "bump back in"--this creates a clean look. there is still the channel/groove/"style line" present to give maintain original Dodge design intent. The faint dashed line shows where the chrome bumper would have been (but is no longer there).

 

Here is a pic of the stock front bumper without anything attached. It could be cut up and made into what you have in mind but all the holes for the trim will have to plug welded and possibly some pieces made to fill the gaps but it could be done. Having someone make die to stamp out a new bumper lower section or whole bumper is not going to be cheap. Custom fab shops would do it the same way as i described or find another bumper with the same contours and mate the two. Either way it will have to chromed after the metal work was done. I plan on moving my bumper back on my Indy to have a more flush look. I will have to cut the sides to keep where the bumper ends but mine is a painted bumper so no chroming expense just paint prep.

 

Oh, the work (and expense) is considerable either way, which I've known from the outset, hence my initial plan to see if it could be, as I've previously said, mass produced as an OEM-type replacement at those cost/price levels to the consumer. I've seen that image before (LMC Truck in my case) and having partially disassembled the front bumper assembly a few months back, have known about the swiss cheese look.

Last week was disassembly and 3D scanning of the bumper assembly. The two objectives were to install the new lower grey plastic trim pieces and to scan the bumper as a bare chrome unit.

The scan dots here are to help orient the scanner when scanning trickier objects, which with this bumper the trick being a very reflective surface. I've been learning the scan tool and this would be the second time using it. I wanted a scan of the bumper assembly complete--even if this was before replacement of parts--for use in CAD.



All the holes present, including all carriage bolt mount points (6).



3D scanning companies will sell a "matte spray" to get scanners to track reliably over reflective surfaces. Since I didn't have any (who does?), didn't want to order any, wait days to get it, and then worry about it affecting the surface, I used the next best thing: car wax, in the applied state. Perfect matte surface, with the benefit of shining up the bumper in the process (post-scan).



This is the scan result. You can see how the scan dots, which I left there. With the applied car wax, the scanning was a breeze. This data gets converted into something a CAD program can use and from there the bumper can be redesigned. I may have a cleaner look as my goal for doing so, but with this data, a bumper with tow hooks or winch mount points or a larger center opening can be designed. We aren't limited to angular or bulky aftermarket designs that don't match the truck's lines or add too much weight or just look ugly. This is the vision. All those 4th gen HD's and Power Wagons with their bumpers purposefully designed with hooks and winches in mind can happen with this or similar redesign. But it starts with starting with the stock bumper and the overall design of the truck and working from there. At least if one wants something that looks like Dodge offered a Power Wagon package from the factory.



As a semi-addendum, to replace the plastic bumper duct/fog lamp hole moldings, the bumper has to be removed. Thankfully the bumper is only 2.0mm thick and not that heavy. Comes off pretty easily. Even access to the 18mm nuts is good.



All the holes:



Quick Photoshop of no holes, with the top cap and air dam installed. It's a clean look, even if it isn't the full initial vision shown in the first post of this thread. Just trying to visualize it for everyone here.

 

what scanner are you using?

 

Shining 3D Einstar. Amazon only. Scanners get super expensive, and in short order, and this is very modest given the capability, thankfully. There is a scanner for a few hundred less, but it seems like many or enough people have serious enough trouble with it that it's not worth the hassle. Einstar reviews are on average good, and I've been able to figure it out well enough to get results I wanted. There is a learning curve, and I'm still on it, but it's been more than workable. While it scanned the bumper well, it struggled with scanning the satin-y black stock upper air box (that flows air into the TB) I have for another project. It seems to be picky about certain kinds of lighting, and maybe it finds black objects with some shine a bit tricky.

The scanner--especially when paired with a CAD program with access to 3D printing, CNC, etc--is an immensely powerful tool that can not only help with bringing new products into existence, but also in preservative efforts. We're working on 20-30 year old trucks that face less and less support as years go on, understandably so. The new stuff has its support, is incredibly capable, but also is quite complicated. 2nd gens aren't saints, but they are a lot simpler. I don't know what the world has for all of us in 5 or 10 or 15 years, but if we're pointed in the direction of keeping the older stuff on the road (as the more "practical" choice), then I'd like to bolster support in that effort where I can. Or...just be able to scan '30s Duesenbergs, Cords, Auburns, and Stutzes so we can recreate the sheetmetal in CAD and stamp out new panels to remake the cars because they're gorgeous. You know, normal stuff.