Cattle Guard - Lightweight Bumper Install - 4-Wheel & Off-Road Magazine

Original parts are always a compromise, be they tires, drivetrains, or even bumpers. A factory front bumper needs to fend off small cars, look decent, and be mileage-friendly. Because of the latter, bumpers are usually quite close to the ground, which messes up the approach angle. And if there are heavier and bigger things in your pickup’s path than just pesky small cars, then the somewhat flimsy factory bumper doesn’t stand much of a chance.

cattle Guard Lightweight Bumper Install bumper On Ram Truck Photo 51036897

A Tasteful Alternative
After a year of searching for a replacement bumper for this ’10 Hemi Dodge, Fred Williams one day pointed us towards Aluminess, a small Santee, California, company that builds aluminum replacement bumpers. Why aluminum, you ask? With today’s pickups having the front axle so far back, any weight added up front really impacts the ride and handling, and not in a good way. Aluminum allows for a strong bumper without the weight penalty. Aluminess offers both a gas and a diesel Ram aluminum winch bumper, but the gas bumper is more compact since it doesn’t need to clear the charge air cooler.

On our quest for an increased approach angle, getting a really big box (118 cubic feet, to be exact) wasn’t necessarily a good thing. Luckily the size was only because Aluminess wanted to package the bumper extremely well. Without all the 2x4s, cardboard, and the pallet, the bumper itself only weighed 1.8 pounds more than the stocker. Combined with their respective bracketry, the Aluminess outweighed the stocker by 4.4 pounds, and that includes a grille guard and stout front receiver.

Vertical Diet
At only 12 inches off the ground the Dodge factory bumper does help keep air from ending up under the vehicle, which helps with mileage, but it kills the approach angle. According to our measurements the angle increased by a whopping 50 percent—from 20 to 30 degrees. That alone could be worth the price of admission on a trail-driven pickup. That the Aluminess version is also a heck of a lot stouter is helpful no matter where you drive. It was primarily the frequent deer and elk encounters that made us look for something more protective for the Dodge’s nose. It always was one according to the emblems, but now it actually can ram, and live to tell about it.

PhotosView Slideshow What all comes in the huge 87x47x50-inch box? Not a lot, really: a 70-pound powdercoated expedition-style bumper, the receiver, instructions, and three bags of fasteners. Disregard the two brackets shown because Aluminess has since changed to simpler, stronger versions. Removing the factory bumper can be done by one person using care, two ratchet straps, and a floor jack. Any tow hooks, foglight wiring, or block heater cord must be disconnected first, then the four to five plastic push-in fasteners supporting the “splash shield,” and finally the two bolts per side that actually hold the bumper in place. Having the front receiver was a big help when we were positioning the Aluminess alone, using a contraption we had lying around. A simple piece of 2x2 square tubing would work fine if your floor jack lifts high enough. Don’t even try to insert the paired factory bolts at this point; but rather, stick drifts or small screwdrivers through the holes for now. With the bumper safely hanging on whatever you used instead of the bolts, and supported by a jack, reinstall the factory bolts one side at a time and snug the nuts down enough to hold things in place, but not tight. There’ll be some adjustments to do. The pickup was half a bubble off (just like us), so that’s what we set the bumper to match. Except then the sides of the bumper didn’t line up with the body. Keep adjusting until all the gaps and distances are to your liking, then torque the nuts down for good. Aluminess redesigned the support brackets since they wouldn’t work with this prototype bumper, so we’re not sure what your bumper will come with. We made our own supports out of 3⁄8-inch aluminum plate and bolted them to the unused holes in the bumper’s side plates. Securing the receiver is done with eight of the included 3⁄4-inch Grade 8 bolts, washers, and lock nuts, four in a vertical and four in a horizontal position. Six of them are accessed through the 3x15-inch lid for the storage compartment. At 33 inches wide, 91⁄2 deep, and 4 high, there’s room for some stuff in there. Cables for a quick-disconnect winch should fit through the existing holes in the rear, and the production models will have drain holes. There will also be some much larger holes in the rear to allow extra air to reach the radiator.

Useful Extras

PhotosView Slideshow A set of Warn’s excellent SDB-160 driving/spot lights were added to help avoid finding out just how stout the Aluminess bumper is compared to, say, an elk. They were originally meant to go in the 6-inch holes in the face of the bumper, but that didn’t quite work out, so those were filled with a pair of Warn W350F foglights instead. Aluminess can make the bumper with 8-inch holes should you want to use larger lights there. Eventually we’ll get stuck again, which is why a Warn VR8000 was part of the plan, and it’s now useable for pulling either from the front or rear, using a Warn Winch Carrier. With Warn’s Quick Connector Kit at the ready within the lockable box, it only takes a minute to make the winch operational. And since the VR8000 comes with the tried and true, uber-intuitive, old-style remote, it doesn’t take any time to spool the 5⁄16 cable in the correct direction, on the first try.

In a Few Words
Good: Lightweight yet strong, good looks, great approach angle.
Bad: Fuel mileage takes a hit.