Custom rear bumper build

[foxwar71]

Now for some actual tech. Are you going to re-use the hitch, or had you given any thought to integrating a hitch into the bumper? Also, any plans for a new CB mount, as I see your old one was attached to the bumper?

I've decided to ditch the stock hitch setup. More then likely, I'll add something to the bumper. The hitch will mainly serve the purpose of a place to put a hitch-mounted vise setup I'm gunna make. I figure theres the slim chance I might actually tow a small trailer with a quad on it, so I should be enough for that too. I haven't really put much thought towards the CB whip, once I make the tire swingout I'll probably mount it on that.

 

[XJFisher]

Once the 4"x2" fit inside, it was time to drill out the mounting holes and make a new nutstrip outta a 1 1/4" wide peice of 1/4" that would fit inside the rec tubing. all mounting hardware is 1/2" Grade 8 bolts and nuts.

i am doing the same thing that you did. i have cut out my bumper so the 4" by 2" will fit, but where i am stuck is how to mount it. i would like to do the way you did by taking a peace of 1 1/4" wide flat bar and welding nuts on it, but is there any other way that you can mount it with out doing that so it is strong enough for recovery points??

 

[Gaius]

Yeah, how are you mounting the bumper mounts (2x4 tubing) in the frame rails?

 

[foxwar71]

Crappy weather, not enough time, and just a bunch of destractions put this on hold for a few weeks. Managed to get a bunch of it done today and get it all tacked together.


Heres the top and front plates tacked into place. I drove around like this for a week.

Pulled everything off to start working on the rest of the pieces. I decided to get fancy and build the remaining 6 plates (angle front and sides & bottom and sides) all outta one piece. I cut the shape needed and cut about 3/16" off the way through so i could bend it into shape. overall, it worked pretty good. grind and trim some spots, whack it with a hammer, and it fits like it should. I also realized i had to remove the bottom angle support piece and make it an inch shorter

Here, you can see the overall shape the face of the bumper will have. angles came out the way i wanted them to, they match the front bumper very nicely.

Gotta finish making some plates for the backside and figure out what i wanna do for the hitch reciever. harbor frieght has jsut a receiver for a couple of bucks, so i might just use that instead. then i gotta cut some more 2"x4" for the lengths under the quarter panels. once those things are done, ill burn everything home

 

[DanMan2k06]

Holy heavy. Any idea on how much that thing weighs?

 

[DesertRunner]

is that all 1/4" ?

 

[Begster]

is that all 1/4" ?

Yes its is.

Hey Ross, looking good. Just make sure you have it done by next week so I can pick it up at the same time I do my front bumper.

 

[foxwar71]

its not that heavy, im still gunna add more to it and make it beefeir/heavier whens its all said and done, ill be able to pick up and install the bumper on my own, so that means its light enough. strength > weight.


Mark, you wish your bumper is gunna turn out as nice as mine

 

[Begster]

its not that heavy, im still gunna add more to it and make it beefeir/heavier whens its all said and done, ill be able to pick up and install the bumper on my own, so that means its light enough. strength > weight.


Mark, you wish your bumper is gunna turn out as nice as mine

Just because you are still going to be able to pick it up and install it on your own doesn't mean it isn't going to be heavy Ross. You forget not everyone is as beastly as you, Mr. "I can bend that metal for you with vice grips." (thanks for doing for me again that by the way)



And you are right, I do wish mine turns out as nice as yours.

 

[foxwar71]

Got the bumper mounted back on the jeep. Got the backside plates made on the corners.

Chopped some lengths of the 2"x4" to use to go under the quarter panels. They extend just enough from the body that a peice of 1.75" tube can mount to it. There will be small sections of tube that will tie this outhanging piece of 2"x4" into the framerails about 8" in front of the leaf spring hanger.

Next up is figuring out the reciever setup and placement. I'll most likely just get this Harbor Freight piece and cut it down and modify to fit my bumper.

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=97095

The reason I want to have a receiver is that there MAY be the one or two times I decide to pull an ATV on a small trailer. I figure the bumper should easily handle something like that. The other reason I want a receiver, is to be able to have a receiver-mounted vise. I was planning on making something, but then I was browsing around HF and found this.

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=66260

 

[tusk762]

looking good man

 

[MG2000XJ]

looks great, quality work

 

[Begster]

The other reason I want a receiver, is to be able to have a receiver-mounted vise. I was planning on making something, but then I was browsing around HF and found this.

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=66260

Remember when we were in HF looking at those pitiful welders? They probably used those to weld that thing together. Knowing you, you will probably rip it apart first time you need to do something with it. I vote you make one.

 

[foxwar71]

I fail, I have totally forgotten to update this thread. The bumper is done for now, I'll be adding a couple of gussets and support tie-in tubes to the side pieces under the quarter panels once I add rear stiffeners and shackle boxes. I'll also be using some 1/8" to make a little piece to fit under the tail lights that will follow the contour of the body, hatch, and light.


Off came the bumper and the top plate so I could setup the reciever. Then I proceeded to weld the crap outta it. Be sure not to go too fast and warp stuff. I like the "weld, take pictures, weld some more, drink adult beverage, repeat" method the best.

All flap wheeled and pretty and smooth

Shot it with some Rustoleum Auto stuff that is made not to fade and all that good junk. I've had great luck with it, my front bumper and front fenders are done with the same stuff and it looks great. It even almost matches the factory black. Here she is all mounted and bolted up.

 

[time2getdirty]

that is a beauty! want to make me one?

 

[Dundy]

that is a beauty! want to make me one?

Ross, you won't even have to pay for shipping...You could just throw it to him! Oh and I am definitely gonna need a rear bumper within the next few months...mine's hangin' on by a thread.

 

[fasteddieyj]

Man that's a great looking bumper. Any updates?

 

[jeeperjohn]

Really nice work dude!

 

[ROBZ95Xj]

Man that's a great looking bumper. Any updates?

its taken a few good hits, bumper didnt bend, but the unibody did, no other updates that i know of, he keeps breakin before he can test out the bumper more

 

[foxwar71]

its taken a few good hits, bumper didnt bend, but the unibody did, no other updates that i know of, he keeps breakin before he can test out the bumper more

It been kicking ass. like Rob said, ive dropped off a few ledges and bent the back of the unibody up but the bumper is still fine. once i get the subframe plated and shackle hangers built, im gunna add finishing details like under the tail lights and a brace for the corner pieces and a trie carrier at some point.