xpedition xj-eh!
NAXJA Forum User
- Location
- Calgary Alberta Canada
So here goes, my first "build" post of any kind. I've been reading this forum vigorously and hacking away on my XJ for quite some time now. There isn't anything radically different about my bumper or carrier but I thought I'd share what I've done and how I went about it because after all, my work is the combination of ideas from other peoples threads. I'm no tradesmen but after working days as a computer programmer, I feel the need to work with my hands. I work on this thing after my wife and three kids have gone to bed. My budget is pretty limited so when I started my Jeep project, I figured I could either buy a handful of things, or buy a welder and try my luck at building all the stuff I wanted. I choose the later, which has taken longer but I've learned a ton in the process and am having a blast doing it. So with that intro out of the way here is my bumper.
1) Do the typical cutting to allow the bumper mounts to be inserted into the frame rail
2) Cut up some 2x4 steel to fabricate the bumper mounts. I have a gas tank skid that needs to use the furthest hole.
3) Gather some "stuff" like 2x5 steel and a 1" bolt and oilite bushings for the swing out carrier hinge
4) Make the 2x5 roughly follow the curve of the tailgate by cutting slits in the back, bending the ends and then weld it to the mounts
...Ok, here is where my build report falls apart. I was shooting photos throughout the build but for a large part of it I didn't realize that my memory card wasn't in the camera!!
5) Make a swingout tire carrier that conforms to the contour of the bumper out of 2x2. Add a small gusset and some angle iron with rossettes near the hinge just for good measure. Here you see it painted in a white base coat of appliance epoxy enamel paint. Final color will be black.
... here is where I jump ahead a bit due to lack of intermediate photos
6) Angle up the ends of the 2x5 and box them in. Add some 1.5x2 steel to go under the folded rockers. Create some "hats" to go under the tail lights. Hack apart a trailer hitch from a Ford Windstar and use the receiver to mount in bumper. Add gussets on back side of bumper to add strength to receiver. Add some bits and bobs to mount the tire carrier. Now, paint it all in a base coat of epoxy enamel appliance paint (tough stuff, and cheap). In the future, I may add some supports for the 1.5x2 to the frame rail under the rocker.
(see next post due to picture limit...)
1) Do the typical cutting to allow the bumper mounts to be inserted into the frame rail
2) Cut up some 2x4 steel to fabricate the bumper mounts. I have a gas tank skid that needs to use the furthest hole.
3) Gather some "stuff" like 2x5 steel and a 1" bolt and oilite bushings for the swing out carrier hinge
4) Make the 2x5 roughly follow the curve of the tailgate by cutting slits in the back, bending the ends and then weld it to the mounts
...Ok, here is where my build report falls apart. I was shooting photos throughout the build but for a large part of it I didn't realize that my memory card wasn't in the camera!!
5) Make a swingout tire carrier that conforms to the contour of the bumper out of 2x2. Add a small gusset and some angle iron with rossettes near the hinge just for good measure. Here you see it painted in a white base coat of appliance epoxy enamel paint. Final color will be black.
... here is where I jump ahead a bit due to lack of intermediate photos
6) Angle up the ends of the 2x5 and box them in. Add some 1.5x2 steel to go under the folded rockers. Create some "hats" to go under the tail lights. Hack apart a trailer hitch from a Ford Windstar and use the receiver to mount in bumper. Add gussets on back side of bumper to add strength to receiver. Add some bits and bobs to mount the tire carrier. Now, paint it all in a base coat of epoxy enamel appliance paint (tough stuff, and cheap). In the future, I may add some supports for the 1.5x2 to the frame rail under the rocker.
(see next post due to picture limit...)
