DIY Aluminum Bumper Shims

I thought I would do a small write up on giving people the idea to make your own aluminum bumper shims for those who might have access to aluminum sheets. As I work with aluminum all day and have a vast amount of access to multiple types and thickness of aluminum, I decided to make my own from a few tools I have at home. Even though it's kind of a PITA process to save $100 ish, it's worth it! I'll try to put it in order the best I can, and I will say this is a small write up as the job is an easy Job.

1: Back out one side of the bumpers nuts about 75% of the way back, make sure to keep them threaded so the bumper don't fall off.

2: Take the other sides nuts completely off that your working on installing the shim first.

3: Cut a piece of cardboard out and clamp in on the bumper bracket that's attached to the bumper itself, then trace it with a permanent marker.

4: Once traced, take out and cut. Then lay the cardboard on your aluminum sheet then trace. Then cut with whatever cutting tool you have. An air compressor and dotco will take a very long time if it's a 1/2" thick sheet like I used, therefore I opted to use a metal cutting miter saw.

5: Once cut, finish the edges with a dotco to break sharp edges and look finished.

6: clamp back onto the bumper bracket and use something sharp to circle the holes of the bumper bolts. Make sure to be as accurate as possible and go all the way around the hole completely.

7: Use a smaller drill bit such as a pilot bit to center directly into the center of the hole. It's important to try and be as close to the center as possible.

8: Once starter bit is all the way through, step up your bit sizes and use a line to help keep the temperature down and make a cleaner hole. If you have access to a drill press, I recommend using one!

9: Once holes are drilled, chamfer both side of the holes. I'd also recommend drilling a couple sizes up from the actual bolt diameter to help with alignment and ease of installation if the first starter pilot hole was slightly off center.

10: DONT INSTALL YET! Take that plate and trace it onto another sheet of aluminum to make the mirror opposite side for the other side of the bumper. THEN install.

11: Once installed, remember to keep the nuts loose but threaded on the newly installed shim side, then repeat the process for the other side.

 

Very cool.