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Old 02-23-2011, 10:20 AM   #1
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Building bumper

My CJ5 came with a 4x4x 1/4" steel bumper welded to the end of the frame rails. Besides being heavy It was also quite ugly looking, like some kind of bash bar meant for forced home entry! So I cut it off a put a TJ bumper on it. Realizing I had a good piece of metal to work with I figured I would attempt to make my own bumper. This is where I'm at right now. Ordered some shackle mounts and those will go on next.
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Old 02-23-2011, 10:23 AM   #2
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More pics
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Old 02-23-2011, 12:15 PM   #3
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Looks good just cap off the ends and it will look realll nice. You could add tabs for some lights too. Just a thought.
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Old 02-25-2011, 10:51 AM   #4
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Looking good! Couple of questions...
1- how easy (or tough) was it to fold the angle tab? Did you use a torch to heat it or just hammer away?
2- how are you gonna mount it? Drill holes or add a bracket?
3- any plans for a receiver hitch?

I'm going to start my bumper this afternoon and am trying to get as much info before I begin.

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Old 02-25-2011, 11:52 AM   #5
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Added shackle tabs today. Need to weld then completely when I get more welding gas.
After cutting the notches for the tapered end I used a clamp to bend them into position. Was very easy and needed
no head or pounding with a hammer
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Old 02-25-2011, 11:57 AM   #6
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I hope to use the back of the shackle mounting tabs to secure it to the frame
There are existing holes in the frame rails I hope to use but I'll see when I get there. This will recess the bumper a few inches towards the grill
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Old 02-25-2011, 12:38 PM   #7
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Oh, ok. You're going to make it the front bumper. I misunderstood and thought it was for the rear. That'll look good up front for sure. You gonna leave space for a winch plate?

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Old 02-25-2011, 12:54 PM   #8
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No winch. This is a beach Jeep and I figure I would never use it anyway!
I will make a rear bumper after seeing how easy it was to make this one. I'll put a receiver hitch and a pivot for the spare tire.
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Old 02-25-2011, 09:28 PM   #9
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Shackle tabs welded in
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Old 02-25-2011, 11:15 PM   #10
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That front bumper looks very, very familiar. Ha
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Old 02-26-2011, 09:09 AM   #11
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Hazzo1 I guess it's true that great minds think alike. I just went to your threads and
saw your bumper fab, very nice. I still need to incorporate a few more design ideas though before I'm done.
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Old 02-26-2011, 08:12 PM   #12
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looks good, be sure to post a finished pic.
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Old 02-26-2011, 08:51 PM   #13
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Nice welds. What are you plans for finish? Are those tabs through welded. 4 x 4 ought to be strong enough for sure!
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Old 03-04-2011, 06:27 PM   #14
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Welded the ends and ground them to shape. Not sure of the finish yet.
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Old 03-04-2011, 08:11 PM   #15
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Looking good! I'm almost to the point of welding mine up too.
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Old 03-06-2011, 08:13 AM   #16
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In the attempt to lighten the bumper I laid out some cut-outs. After looking at it I thought it looked like cloths hanger!
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Old 03-06-2011, 08:19 AM   #17
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I started filling in the pieces I cut out. I think I just want an excuse to weld and grind. I'm going to weld a plate to the end of the shackle mounts so they bolt directly to the frame. I may add hoops over the driving lights
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Old 03-06-2011, 10:43 AM   #18
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What you have done is nice and it's fun working with tools but I wonder if opening the front of the bumper like that how the jeep will handle it when you go mudding or through water or trailing. The bumper just becomes a catch-all and then how do you clean it out?
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Old 03-06-2011, 11:27 AM   #19
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Jeep will only see sand while I own it. So a little blast of air will clean it out. There is also slots on the bottom that will drain water
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Old 03-06-2011, 11:49 AM   #20
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That should work. Looks good!
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Old 03-06-2011, 12:02 PM   #21
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Wow now I have an idea! Thanks!!! My 95 YJ front bumper is u shaped and bolts to frame rails. I've been trying to think how I could use some 1/8th inch flat stock to make a bumper. Guess I just need to check with steel outlet for some square tubing.
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Old 03-06-2011, 05:56 PM   #22
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where did you get the shackle tabs, I need some for my bumper.
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Old 03-06-2011, 06:00 PM   #23
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Competition4x4 on eBay. He can make them any length and he ships very fast.

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