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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659  | Conversion of 460/461 tow pin bumper with Dutch Army tie downs As you may know, Dutch Army 290GD's have got a specific military front bumper which incorporates a set of tie down brackets (and also fold up number plate and some end-cap flag holders) (picture 1). I was able to get a set of these tie downs (which are an integrated part of the bumper mounting brackets) and reproduced them. These 290GD tie downs/bumper brackets are heavier than standard bumper brackets. Thickness is 8mm and bumper bracket bolts are M16x1,5 (fine thread), whereas my 460 has got 7mm bracket with M14 bolts. - Original and duplicated part (pic 2). -8 mm lasercut bracket and rings to make the tie-down eye (pic 3). - My old 460 tow pin bumper which I used for testing this modification (pic 4). - First cut off the original brackets (pic 5). - To be able to weld the brackets all the way in and to the bumper like MB does, cut out a window section to give the sufficient clearance for welding (pic 6 and 7). - And do this on both sides (pic 8). - Test fitment, fits perfect. As you can see, this bracket is welded all the way up to the front of the bumper (pic 9). - But first weld the rings to the brackets to make the correct tie-down eye. I chamfered the rings on a lathe with a 2mm 45 degree chamfer. Can also be done on a grinding wheel of course (pic 10). (4 (Small).jpg) (IMG_5280 (Small).JPG) (IMG_5241 (Small).JPG) (IMG_5285 (Small).JPG) (IMG_5293 (Small).JPG) (IMG_5294 (Small).JPG) (IMG_5295 (Small).JPG) (IMG_5306 (Small).JPG) (IMG_5300 (Small).JPG) (IMG_5324 (Small).JPG) Attachments ----------------  4 (Small).jpg (126KB - 1 downloads) IMG_5280 (Small).JPG (84KB - 1 downloads) IMG_5241 (Small).JPG (61KB - 1 downloads) IMG_5285 (Small).JPG (165KB - 0 downloads) IMG_5293 (Small).JPG (154KB - 0 downloads) IMG_5294 (Small).JPG (166KB - 1 downloads) IMG_5295 (Small).JPG (174KB - 0 downloads) IMG_5306 (Small).JPG (155KB - 1 downloads) IMG_5300 (Small).JPG (134KB - 1 downloads) IMG_5324 (Small).JPG (75KB - 1 downloads) | |
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: Conversion of 460/461 tow pin bumper with Dutch Army tie downs - With a 20mm rod, I lined up the rings with the bracket eye (pic 1). - Then some tag welds (pic 2). - And some heavier welding to weld all 4 rings to the brackets (pic 3). - Then tag weld the bracket in the bumper. Outer distance of brackets should be 700mm (because I found this was a pretty beat up bumper, I had to do some more metal repairs to it and had it sandblasted in between. When only doing the bracket welding, no need for complete sandblasting) (pic 4). - Brought in the G for a test fitment (pic 5). - Old and upgraded bumper compared (pic 6). - Here you can see the difference between the standard tow pin bumper brackets and the heavier Dutch Army version brackets (8mm thickness, M16 boltholes) (pic 7 and 8). - Because of the larger bolts used on this bumper, you will have to enlarge the front and rear bumper boltholes on the frame-brackets. A dremel can be used for this (pic 9 and 10). (IMG_5333 (Small).JPG) (IMG_5331 (Small).JPG) (IMG_5353 (Small).JPG) (IMG_5358 (Small).JPG) (IMG_5389 (Small).JPG) (IMG_5392 (Small).JPG) (IMG_5393 (Small).JPG) (IMG_5394 (Small).JPG) (IMG_5396 (Small).JPG) (IMG_5397 (Small).JPG) Attachments ---------------- IMG_5333 (Small).JPG (109KB - 0 downloads) IMG_5331 (Small).JPG (110KB - 0 downloads) IMG_5353 (Small).JPG (128KB - 0 downloads) IMG_5358 (Small).JPG (151KB - 0 downloads) IMG_5389 (Small).JPG (141KB - 0 downloads) IMG_5392 (Small).JPG (175KB - 0 downloads) IMG_5393 (Small).JPG (165KB - 0 downloads) IMG_5394 (Small).JPG (165KB - 0 downloads) IMG_5396 (Small).JPG (114KB - 0 downloads) IMG_5397 (Small).JPG (122KB - 0 downloads) | |
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: Conversion of 460/461 tow pin bumper with Dutch Army tie downs Test fitment was okay, so time to finish welding the brackets to the bumper and close the window section on the rear of the bumper: - The section of old bumper bracket makes a nice foundation to make some corner welds (pic 1). - Welding inside the bumper using the window cut-out (pic 2). - And closing the rear of the bumper welding the window section back in. After paint/powdercoat it will be smooth and clean (pic 3). - Welded bumper on the G (pic 4, 5 and 6). (IMG_5412 (Small).JPG) (IMG_5414 (Small).JPG) (IMG_5420 (Small).JPG) (IMG_5398 (Small).JPG) (IMG_5402 (Small).JPG) (IMG_5400 (Small).JPG) Attachments ---------------- IMG_5412 (Small).JPG (125KB - 0 downloads) IMG_5414 (Small).JPG (116KB - 0 downloads) IMG_5420 (Small).JPG (121KB - 0 downloads) IMG_5398 (Small).JPG (135KB - 0 downloads) IMG_5402 (Small).JPG (116KB - 0 downloads) IMG_5400 (Small).JPG (125KB - 0 downloads) | |
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| Boy G Expert Date registered: Feb 2007 Location: Bushveld, South Africa Vehicle(s): Diesel G's: 617A and 602 Posts: 1683 | ||
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hipine Date registered: Jul 2006 Location: US, CO, Bailey Vehicle(s): 460 1980 280GE w. 617A  | ||
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | Re: Conversion of 460/461 tow pin bumper with Dutch Army tie downs Boy G - 4/2/2017 2:33 PM Looks mighty fine. Can this arrangement still accommodate a brush guard? Sure it can, see some pics below. Accomodates the 460 brush guard and also the Rotlzer winch frame. Only the standard 460 foglights have to be repositioned. (IMG_5410 (Small).JPG) (IMG_5411 (Small).JPG) (IMG_5367 (Small).JPG) Attachments ---------------- IMG_5410 (Small).JPG (89KB - 0 downloads) IMG_5411 (Small).JPG (111KB - 0 downloads) IMG_5367 (Small).JPG (144KB - 0 downloads) | |
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| Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004  | ||
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: Conversion of 460/461 tow pin bumper with Dutch Army tie downs For these owners with older 460 frame, the frame bumper brackets can be reinforced by welding in an angle bracket similar as the later 460/461 frames. Not a bad idea when you're thinking of doing heavy pulls with your bumper. See pic 1. Encircled is the angle bracket which is not present on older frames (picture thanks to Guido). Not sure when MB incorporated this angle bracket btw. See pic 2. Bracket is made out of 4mm steel. Can be homemade, but I've copied the design and I can supply a set for people who are interested. gr. Bram (IMG_1902p (Small).jpg) (Angle bracket RH.jpg) Attachments ---------------- IMG_1902p (Small).jpg (86KB - 0 downloads) Angle bracket RH.jpg (34KB - 0 downloads) | |
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| diesel_jim Veteran Date registered: Jan 2014 Location: N Wiltshire. UK Vehicle(s): LR Defender 110, 1989 W460 SWB Posts: 114  | ||
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: Conversion of 460/461 tow pin bumper with Dutch Army tie downs For people interested to modify the 460/461 tow pin bumper with a set of Dutch Army tie down brackets, here's the set I can ship: Set consists of 8mm lasercut steel brackets and correct MB hardware: 2 x bracket 8mm lasercut 4 x ring to construct the tie down eye 8mm lasercut 4 x M14x1,5 bolt (10.9 strength) 4 x M14x1,5 nuts (self locking, 10.9 strength) 8 x washers M14 PM for info on price and shipping options. gr. Bram (IMG_6437 (Small).JPG) Attachments ---------------- IMG_6437 (Small).JPG (81KB - 0 downloads) | |
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: Conversion of 460/461 tow pin bumper with Dutch Army tie downs Got my army tie-down converted bumper back from powdercoating, pretty neat to see it finished. People interested in doing this 'Dutch Army tie down' conversion with 8mm lasercut thick brackets and M14x1,5 hardware, pm me for price and info. gr. Bram (IMG_9329 (Small).JPG) (IMG_9332 (Small).JPG) Attachments ---------------- IMG_9329 (Small).JPG (166KB - 0 downloads) IMG_9332 (Small).JPG (115KB - 0 downloads) | |
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| diesel_jim Veteran Date registered: Jan 2014 Location: N Wiltshire. UK Vehicle(s): LR Defender 110, 1989 W460 SWB Posts: 114 | ||
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