![]() I installed all of the parts (one last time!) and bolted the bumper up to the Sidekick (one last time!) I have used Permalac on some of my welding projects around town (handrails, etc.) with good success it has UV inhibitors and should make the paint last much longer. Previous experience with spray paint has taught me that it doesn’t last for more than a year or two out in the sun, so I shot on a few coats of satin Permalac. I shot on a couple of coats of self-etching primer, followed by some wet sanding, then a few coats of rattle can gloss black. I installed the bumper on the Sidekick again just to make sure there were no interference issues with all of the accessories installed, then removed it for paint. I even cut out some Suzuki “S” emblems on my CNC plasma table to dress up the bumper. Next I installed the air compressor, lights, the winch, and the winch solenoid pack. The bumper was re-installed on the sidekick to test fit the winch and mark holes for drilling Once the tanks were fully welded, I pressurized them with shop air and used soapy water to check for leaks, and then installed the compressor. I decided to enclose the outside wings and turn them into air tanks. I had a couple of 8” LED light bars sitting on a shelf in my shop this was the perfect application. Once I had the basic shape tacked together, I added the lights. ![]() If I didn’t like it, I cut it off and made a new piece. If I liked the look, I tacked it in a few more places. Then I cut some cardboard templates, transferred them to steel, cut them out, and tacked the steel into place. I grabbed a scrap of 3/16” plate, bolted it to the frame, drew some lines on it with a soapstone, then fired up the plasma cutter. I didn’t do any of that for this project. I’m happiest when all of my bolts and nuts are lined up in a neat row, all of my material is accounted for, my welders are full of filler metal and shielding gas, and I have some sketches of my project up on the whiteboard. I like to fully plan a project before starting it. After some additional thought, I decided to install a Viair 400c air compressor and integrate some air tanks into the bumper body, as well. Basic idea for the bumper: I needed to protect the front fenders and radiator, allow for full travel of the front suspension, house auxiliary lights, provide for easy and safe tow strap and shackle connections, and support a Warn M8000 winch. After staring at the front of the sidekick for a bit, I decided to go with the plate. I had a few winches, lights, tow hooks, D rings, and more. I had several sheets of 3/16” plate steel. Tube or plate? Did I want the minimalist prerunner look, or the angular stealth look? What features did I want to build into this bumper? I had a pile of tube and a tubing bender. But, I decided that I wanted something more. How could I put a good-looking and functional front bumper on this sidekick? I thought about buying and modifying one of the offerings from the Suzuki aftermarket there are some decent looking bumpers out there. I was growing tired of looking at it each morning, so the gears began to turn. I have also added some character to it throughout the years rocks, brush, and dirt all had left their marks on the plastic. ![]() ![]() The factory front bumper on my sport was in sad shape the previous owner hadn’t been kind to it, and I had, um, “clearanced” it with a sawzall to allow room for bigger tires. Since Sidekick bumpers bolt to the frame rails, most aftermarket bumpers designed for the Sidekick simply won’t work on the Sport submodel. Unfortunately, this spacing causes some problems in the aftermarket. The frame rails are spaced a few inches further apart to accommodate a different engine. SEASIDE, OR – One of the great things about the 1996-1998 Sidekick Sport is its wide stance from the factory. Custom Front Bumper for a Sidekick Sport Story & Photos by: M.
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