Eric,

It’s expensive to polish any metal.  I’m not taking polishing after electro plating ( that’s not cheap either), but polishing from raw stock.

You know the drill, work up thru series of finer abrasives, and buffing compounds….
It’s tedious :-)

Ab

> On Aug 3, 2022, at 6:56 AM, Eric Caron <ericcaron96@comcast.net> wrote:
> 
> Then again, this is Aluminum so maybe rust is not a factor so drilling the needed holes is no big deal?  I’m still learning!  I didn’t know it was expensive to polish Aluminum rather then paint for example.
> 
> Looking forward to hearing how the orange bumpers look on the bus!
> 
> eRic 
> 
> 
>> On Aug 3, 2022, at 9:49 AM, Eric Caron <ericcaron96@COMCAST.NET> wrote:
>> 
>> Bumper dreams,
>> 
>> Not practical but I  always loved the way the early Bay window bumpers curved around and became a step to get into the van.  I wonder why that was only for a couple years.
>> 
>> On the practical side.  My second van has GW steel bumpers, but the front one had no holes for a from License plate. 
>> 
>> I’d recommend two holes in the correct place for a bracket so that they get pained and are ready. I hate drilling into a newly painted piece.
>> 
>> Of course Alistair probably has a bunch of cool license brackets ready to go.  
>> 
>> 
>> Eric 
>> 
>> 
>> 
>>>> On Aug 2, 2022, at 9:57 PM, Alistair Bell <albell@SHAW.CA> wrote:
>>> 
>>> If you want, yes :-)
>>> 
>>>> On Aug 2, 2022, at 5:11 PM, Bruce Todd <beeceetee@gmail.com> wrote:
>>>> 
>>>> Will they come with bottle cap removers?
>>>> 
>>>> BT
>>>> 
>>>>> On Tuesday, August 2, 2022, Alistair Bell <albell@shaw.ca> wrote:
>>>>> Hey Bruce. I hope to make more bumpers, well I have to make at least 2 sets. We will see how it goes.
>>>>> 
>>>>> I’m kinda slightly regretting my orange choice before seeing it. But hey, live a little .
>>>>> 
>>>>> Ab
>>>>> 
>>>>>> On Aug 2, 2022, at 1:28 PM, Bruce Todd <beeceetee@gmail.com> wrote:
>>>>>> 
>>>>>> Or one side orange and the other side brown to compliment Alistair’s best
>>>>>> in class colour scheme!
>>>>>> 
>>>>>> Thebumper looks very nice.  I could also be a beta tester - and you know
>>>>>> where my van currently lives.   I decided to to go with my stock bumpers
>>>>>> and not upgrade to keep project costs somewhat in line.  Anyway if you
>>>>>> begin to roll these off the Bell Industry’s assembly line - you have
>>>>>> another client…I can even pick up factory seconds directly from the factory.
>>>>>> 
>>>>>> Bruce
>>>>>> 
>>>>>>> On Tuesday, August 2, 2022, David Boan <dboan@outlook.com> wrote:
>>>>>>> 
>>>>>>> I think you should paint one side white and the other orange, and promote
>>>>>>> it as an example of the spirit of compromise in marriage,
>>>>>>> 
>>>>>>> Dave B
>>>>>>> Boise
>>>>>>> ________________________________
>>>>>>> From: Vanagon Mailing List <vanagon@gerry.vanagon.com> on behalf of Eric
>>>>>>> Caron <ericcaron96@COMCAST.NET>
>>>>>>> Sent: Tuesday, August 2, 2022 12:40 PM
>>>>>>> To: vanagon@GERRY.VANAGON.COM <vanagon@GERRY.VANAGON.COM>
>>>>>>> Subject: Re: Doing another rear aluminum bumper
>>>>>>> 
>>>>>>> I would love to have my van be orange!  But, white is so darn practical
>>>>>>> for heat when camping.  Also, my wife is anti orange color for us.  Still a
>>>>>>> orange 76 westy still fills my dreams!
>>>>>>> 
>>>>>>> The bumpers in Orange sound great to me!
>>>>>>> 
>>>>>>> Still aluminum can’t just be pretty polished?  I don’t know these things
>>>>>>> but simple care is appealing.
>>>>>>> 
>>>>>>> Eric
>>>>>>> 
>>>>>>> 
>>>>>>>>> On Aug 2, 2022, at 1:34 PM, Alistair Bell <albell@SHAW.CA> wrote:
>>>>>>>> 
>>>>>>>> Hey Eric,
>>>>>>>> 
>>>>>>>> Got a line of beta testers waiting here…. But I’ll put you on the list
>>>>>>> :-)
>>>>>>>> 
>>>>>>>> It’s 1/4” 5052 aluminum. Yes it’s strong enough to stand on, that’s
>>>>>>> important to me too. And the top plate, the standing surface, is flat, not
>>>>>>> slightly angled as in the stock steel. So less chance of slipping off in
>>>>>>> the wet.
>>>>>>>> 
>>>>>>>> Took bumper to powdercoat today. Was going to be all black, a very
>>>>>>> slight texture . But he showed me a gloss orange that so very closely
>>>>>>> matches the orange doors I’ve got on van… so why not, encaps still black.
>>>>>>>> 
>>>>>>>> I can repaint if the orange looks silly
>>>>>>>> 
>>>>>>>> 
>>>>>>>> Ab
>>>>>>>> 
>>>>>>>>> On Aug 2, 2022, at 9:17 AM, Eric Caron <ericcaron96@comcast.net> wrote:
>>>>>>>>> 
>>>>>>>>> Hey,
>>>>>>>>> 
>>>>>>>>> Looking for a Beta tester?  I’ll pay shipping and more!
>>>>>>>>> 
>>>>>>>>> Light, strong, rust proof, and stock like look?  What is not to love?
>>>>>>> And, Bell Industries reputation behind it!
>>>>>>>>> I’m happy with a not perfect version!
>>>>>>>>> I only want to know is it strong enough for one  to stand on to get up
>>>>>>> on the luggage rack or rear of bus?
>>>>>>>>> My stock one on the front wants to bend if I try to step up on it.
>>>>>>>>> 
>>>>>>>>> I’m blind, but why paint?  Would brushed or polished aluminum stand up
>>>>>>> without need of touch ups?
>>>>>>>>> 
>>>>>>>>> Eric Caron
>>>>>>>>>> On Aug 2, 2022, at 11:08 AM, Alistair Bell <albell@SHAW.CA> wrote:
>>>>>>>>>> 
>>>>>>>>>> Four years :-)
>>>>>>>>>> 
>>>>>>>>>> Well , since I measured the stock bumper and drew first model .
>>>>>>>>>> 
>>>>>>>>>> Then this spring I had bumper 3D scanned. More or less fit my measured
>>>>>>> model.
>>>>>>>>>> 
>>>>>>>>>> Then more computer modelling , time wasting .
>>>>>>>>>> 
>>>>>>>>>> The main part of the bumper is quite fast. Cnc router cut panels, 3,
>>>>>>> then held in curve on a jig, top and bottom plates tacked on. Then full
>>>>>>> weld. I tig welded this one, but I’d mig the next.
>>>>>>>>>> 
>>>>>>>>>> Router a chamfer on top weld, flap disc grind the bottom weld to blend.
>>>>>>>>>> 
>>>>>>>>>> It was the endcaps that took the most time. I have I think four failed
>>>>>>> versions. Flat pattern cnc cut, then brake press to bend, then a front face
>>>>>>> and a wee little rear face welded. Grind and blend etc.
>>>>>>>>>> 
>>>>>>>>>> Now that the endcaps figured out, not so bad , or slow .
>>>>>>>>>> 
>>>>>>>>>> So all the hard work done. I’d say less than 4 hours to make one , not
>>>>>>> counting cnc machine cut time .
>>>>>>>>>> 
>>>>>>>>>> Ab
>>>>>>>>>> 
>>>>>>>>>>>> On Aug 2, 2022, at 7:59 AM, Stacy Schneider <vwcrewman@gmail.com>
>>>>>>> wrote:
>>>>>>>>>>> 
>>>>>>>>>>> 
>>>>>>>>>>> That is really nice, you must have 40 hours in it?
>>>>>>>>>>> 
>>>>>>>>>>>                    Stacy
>>>>>>>>>>> 
>>>>>>>>>>>> On Tue, Aug 2, 2022 at 7:54 AM Alistair Bell <albell@shaw.ca> wrote:
>>>>>>>>>>>> Wanted something lighter than my previous and with no trailer hitch.
>>>>>>> Trying to mimic the stock steel bumper.
>>>>>>>>>>>> Got one made well enough to powder coat and use.
>>>>>>>>>>>> https://shufti.blog/2022/08/01/vanagon-making-another-
>>>>>>> aluminum-bumper/
>>>>>>>>>>>> 
>>>>>>>>>>>> Alistair
>>>>>>>>>>> --
>>>>>>>>>>> 1989 Swedish Tristar with Aluminum gates and Atiwe 16" Wheels.
>>>>>>>>>>> Oldest son is an Eagle scout.
>>>>>>>>> 
>>>>>>> 
>>>>>