Lots of factors to consider, some have been touched here.
One that hasn't is application, meaning how one uses their 'Zu.
Don't think this is really that much of a factor. Most of us are kinda proud of our Zu's and regardless of what we use them for, we want them to look tough and offroady, it's a pride thing
IMO, these trucks don't need "crawler" armor. They need something durable, attractive, and inexpensive. Granted, these are relative terms, so I'll elaborate:
durable--more substantial than OEM bumpers.
attractive--simple design with minimal angles/contours and
appendages. Less fab time and material cost
translates to lower finished product price.
inexpensive--least definitive category, I know; factor
margins for fixed and variable costs,
and profit...I'd like to see some offerings
under $200.
this is really a contridiction in terms, don't see how you could do all three.
Durable- a 5 ft chunk rectangular steel would meet this requirement
Attractive- this is what drives the cost of products up, first you have to figure out the design you want and then start cutting the angles and pieces to cover the cut ends. Then you have to cap/weld on the ends, and grind down the welds, figure out the mounting brackets, build the mounting brackets then figure out wheather the bumper is going to be weld on or bolt on, drill holes (mounting bracket isn't as cut and dry and simple as for a cherokee). after you've figured out and constructed the bumper, you'll need the sand, prime, re-sand, and paint the bumper.
inexpensive- If you do-it-yourself, and have access to a mig or stick welder, chopsaw and or metal cutting bandsaw, grinder, and don't factor in your time, you could do one for under $200. I couldn't do one for that when I factor in all the materials and labor. You get what you pay for, if you want quality and craftsmanship you pay for it. If you have the skill and equipment you build yourself a nice bumper, or if you don't care you weld a piece of steel on the front frame horns and be happy with it. Unfortunately, you can't even buy a brushguard/grillguard for under $200
There's a guy on ebay selling Cherokee "crawler" bumpers for around $200 for a pair, front and rear. Others selling bumpers for various makes/models in that range or slightly more, with more "features", and what appears to be competent construction. (That's the big "if" with buying home fab, versus buying from a reputable mfgr, versus making it ones self).
again, you get what you pay for. Another factor in cost is the quantity of the items built and sold. There are alot more cherokee's on the trails/road than Isuzu's. If you know you are going to sell 50 bumpers, you can sell them for less and maintain a profit margin. If I knew that I could sell a bunch of simple design front and rear bumpers, I "might" be able to keep them in the $200-$250 price range
Two factors inherent with home fabrication--"built not bought" carries some weight; the pride of doing it ones self, and second--you get precisely what you want--exact dimensions, features, materiel composition, location of accessories, and mounting/attachment method.
I agree completely, when you build it yourself there is a felling of pride in your finished product. There are a bunch of Zu owners that have great fab skills and it shows in the stuff they build for there trucks. I have that pride feeling with everything I build and sell to others.
I think the trend in armor is moving to home fabrication b/c more enthusiasts are acquiring skills and tools to do these projects, and manufacturers cannot profitably produce a product that is inexpensive enough to outweigh the other factors. In other words--building it myself, getting it exactly how I want it, though it will take some time and energy, but will save lots of money, is more desireable than spending $500-$1000 to get a manufactured bumper identical to the one on the rig down the street, delivered next week.
but isn't your time worth anything, if you figure in your time (pay yourself) many times it would have been more cost effective to just purchase one. If you don't value your time or just happen to have lots of spare time on your hands, this doesn't come into play. I grossly under pay mayself for most of the products I build in order to keep them somewhat affordable. For instance, the going shop rate for most welding shops is $85 per hour(and some also charge per inch/foot of weld), there is between 40ft-50ft of weld (5-7 hours) in one of my rear bumpers, then 3-5 hours of grinding/rewelding low spots, regrinding. Then 2-3 hurs sanding/filling with spot putty, resanding, priming, resanding, paint prep, painting. this doesn't even include the 4-6 hours of time cutting all the pieces and setting them up in the correct position for welding. Could I do it cheaper, probably if I cut some corners with the quality, but that's just not my style. I have always been taught, if your going to do something, do it to the best of your ability and it shows in the products I build.
