Attaching Bumpers

[Bill_B]

Originally Posted by matthewdenny

As an FYI our frame is TIG welded 1" square Aluminum tubes that are 5" from top to bottom (3" in between the tubes).

Here is a cross section of what you might do. If you bring the angle stock to the tournament not cut to length as you'd be using, then it will not be part of your 30 pounds of fabricated material. Do all cutting and drilling on site to save the poundage.

Orange angle stock segments are screwed to back of bumpers with 4 or 6 #10 at least wood screws. Round head will work since they won't contact the frame. The green are bolts for which you have drilled holes through both the frame and the angle stock segments. Do the drilling only after hitching the angles to the bumper and fitting the bumper into place in the frame. If you get a nice long drill bit, six inches or more, you'll be able to get both top and bottom in the same pass. You would also be able to use a nice 6" bolt through all four parts of your attachment system.

Do this in at least two spots on each bumper. If you have a set of red and a set of blue bumpers, put the angle segments in slightly different spots on the bumpers and drill different holes in the frame for each of red and blue sets. Of course you can use the same bolts, but I would get some red and blue sharpie marks around the corresponding holes to reduce frustration trying to fit the bumpers on at color changes.

Good luck. Next year, mount the angles on the bumpers before the fabric goes on and you'll be able to use machine screws or bolts to do it.