Now we come to most of the custom work involved in the project. Not many vendors carry much in the way of bumpers or component protection for K5's. Those who did, were not what I was looking for so I decided to make my own. Both the front and the rear bumpers have gone through a couple of stages of building, I am now happy with what I have and will most likely leave it alone for a while. Both are made from 1/4" and 1/2" thick steel and fully welded. They attach to each frame rail with four 1/2" grade 5 bolts. The main parts of the bumper are 2" x 2" square tube and 2" x 4" rectangle tube. The mounting plates are 1/2" x 4" wide steel plate that go completely though the bumper and have shackle eyes drilled through them for pull points. On the rear I made a tire/gas can carrier. I broke the original one off at Tellico and rebuilt it with a bearing pivot point as well as a new bushing pivot point coming off the body. The front bumper is built in the same exact design as the rear. I have added a winch mount and pre-runner style bar for winch protection to the front, both have receiver hitches built into them as well.

Under the body I built a new cross member/skid plate. The cross member is made of 1/4" thick 2" square tube and the skid plate is made of 1/2" thick steel plate. The skid plate covers the transfer case from any rock intrusions that may occur. I built this after trashing the stock skid plate and putting a good size kink in the stock cross member. One other solid piece of protection are the Heavy duty rocker panels themselves. The stock rocker panels were rusted out, so I cut them off. I replaced them with 2"x3" eleven gauge steel tube. They can take some serious punishment without caving in and they also gave me about 2" better ground clearance at the rocker panels.

Original tire/gas can carrier closed Click for full size image	Original tire/gas can carrier open Click for full size image
Pivot points on new carrier Click for full size image	New carrier open and 0 sag Click for full size image
Front bumper, first incarnation Click for full size image	Front bumper currently Click for full size image
Old skid and cross member AFTER some hammer work to straighten Click for full size image	Mmm BEEFY, new cross member and skid, after some bashing on the rocks Click for full size image

The rocker panels were the most labor intensive part of building this project to date. I have some more modifications that I am going to be doing to them in the near future to make them stronger and more protective of the body. I have also built and installed a set of Bullet Proof spring perches on the rear axle, this was done when I had to move my pinion angle for the new drive shafts.

Stronger boxed steel rocker panel Click for full size image	Rocker panel being tested Click for full size image
New perches are taller and stronger than the stock ones Click for full size image	Ends boxed and holes drilled before installation Click for full size image

Darn, where do I start, there are quite a few minor and custom mods to the old girl that are not covered about. I built a custom grill out of expanded steel. Built mounts for some large off-road lights that are installed behind the grill for protection, not to mention it looks mean like that. Inside I have built and installed a Hand throttle on the stick shift, for those times when you stall on a hill and you need three feet. A set of very aggressive brake and clutch pedal covers, you wont drive this thing barefoot. On the rear axle I have built and installed a truss made out of 2" square 1/4" thick steel. On the dash there is a Cobra c.b. and Garmin g.p.s.. Where the radio used to be are my controls for the Rancho Duel In Cab shock controller, and switches for my off-road lights and my on board air.

Under the hood is a full compliment of K&N filters. A Hehr Power Under hood welding system and of course the on board air compressor and one of the three air tanks. The other two tanks are under the bed. In the bed of the K5 I built a couple of racks that hold all my spare parts, tools and winch accessories as well as my high lift jack and shovel.

Old grill, K5 on a little ledge Click for full size image	New grill with all four lights Click for full size image
Hand throttle mounted on stick Click for full size image	Custom slip proof pedals Click for full size image
Complete K&N filter swap Click for full size image	Hehr Power Arc II welding system Click for full size image

Inside rear storage rack, note the winch is now on the front bumper

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High Lift mounted on rack with full size shovel and 4 way lug wrench

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I have quite a few other modifications planned for the K5 in the coming months. I also have a few other products to install and review and some trial rides to attend. Check back often to see what has been changed, installed, and built over the next few months.

Got a question, check out the Off-Road.com Chevy b.b.s. system and chances are you can find the answers here.