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Old 02-25-2011, 11:11 AM   #1
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Home built rear bumper

Hi all. As the title suggests, I'm going to start my bumper soon (maybe even this afternoon). I've been through quite a few of the posts and am impressed with a lot of the designs. I'm doing my own because I'm too cheap to buy new, and, more often than not I can't find a used bumper that isn't beat to crap. I've got a 3"X6" piece of steel that I'm using. It wasn't my first choice of stock size, but for free I couldn't beat it! My thought is to taper the ends up and back a little, like a crawler style. I'm going to add a receiver to it as well as a couple of shackles. I've heard of other people making them into an air tank, any thoughts on this pro/con? As far as mounting it, I'm going to add a piece of 2"X3", roughly 1-2", to the back of it and attach all that to a 3/8" plate that has the OEM bumperette bolt pattern. I figure being attached that way gives a little more protection without being too far out to hang up when going down a staircase type trail. I've also thought that because it is 6", I might put the receiver into the face of it, rather than just below. This is another decision that is up in the air for now.

Well, hopefully I'll hear back from some of you who have done this before and can give me some tips and pointers. And I'm going to make sure to post pics of the progress.

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Old 03-02-2011, 11:55 AM   #2
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The airtank works well on bumpers like the one your going to build. My dad did his on his CJ. Welded in two 3/8" nipples, one for the air coming in from the compressor and the other for a quick disconnect for the air hose.

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Old 03-02-2011, 12:06 PM   #3
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If you want to go the airtank route, make sure your welds are really good, or your going to end up with leaks.
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Old 03-02-2011, 12:10 PM   #4
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Thanks for that info, Geno. I figure I'll build it as stout as I can an if my welds hold up it'll be an air reservoir. You remember how much pressure your dads tank can hold?
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Old 03-03-2011, 09:21 AM   #5
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We set the pressure switch to cycle off at 85psi and on at 50psi.If welded properly, your bumper will hold up to 200psi. He had a few leaks at first, but we would test it with air, find the leak, grind it out and weld it up again. I suggest using a minimum of 3/16" wall but like 1/4" better with whatever size tubing you go with. All in all it wasnt that bad of a project. And having a quick connect at the bumper is pretty cool. He even found a rubber cap to protect it.
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Old 03-03-2011, 11:29 AM   #6
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Well, I finally had time to get started on my build. Being the first time I've built my own bumper I'm taking a little longer to make sure everything is right before I start cutting. I first found the centerline of the material, then marked out the outside dimensions. I decided to go wider than the stock bumperettes, but narrower than the outside line of the tub. After marking my angles I remeasured everything again and this is what I ended with.
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Old 03-04-2011, 12:48 AM   #7
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Had about an hour to kill tonight and did a little more. Set up the plasma cutter and went to work. I planned on cleaning up the wild cuts with my die grinder, but realized I was out of disks. So hopefully tomorrow I'll get it a lot cleaner, after a trip to harbor freight for disks. Who knows, maybe I'll start welding it as well. Speaking of, I have both a wire feed and a stick welder available. Which would you recommend I use?
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Old 03-06-2011, 09:45 PM   #8
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I'm surprised nobody has responded to your question regarding a wire feed or a stick welder and my recommendation would be: Use the wire feed welder. It is much easier!
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Old 03-06-2011, 10:23 PM   #9
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Quote:
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I'm surprised nobody has responded to your question. Use the wire feed welder. It is much easier!
I, too, was surprised about that. Thanks for your reply though. I had decided to use the wire welder for it anyway.
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Old 03-06-2011, 10:24 PM   #10
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i agree, use wire feed. i personally prefer arc but wires gonna be your best bet, im excited to see how your bumper turns out
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Old 03-07-2011, 12:48 AM   #11
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Originally Posted by jkaufman_95
i agree, use wire feed. i personally prefer arc but wires gonna be your best bet, im excited to see how your bumper turns out
Thanks, and I'm looking forward to finishing it up this week. I just haven't had a lot of time to work on it. But, rest assured, I'll post pics.
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Old 03-07-2011, 05:48 AM   #12
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Nice start. If you go the air tank route, I'd figure a drain for condensation like a compressor...but you'd have to protect from damage (sorry I run air tools for a living and water is bad). If you plan on towing with the bumper I'd look into some frame tie-ins for the factory crossmember. Your bumper will be very stout, but the crossmember you are boltin to is the lightest part of your frame (you have a YJ don't you?). I have found a couple I might copy for mine, but would prefer one that went farther forward than the rear shackle hole/mount.

Here's something like I'm referring to:

http://www.rockhard4x4parts.com/imag...RAMEKIT-01.jpg


Keep posting pics, looks good.
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Old 03-17-2011, 10:16 AM   #13
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lets see some more pics!!
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Old 03-17-2011, 12:08 PM   #14
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Originally Posted by Skytard
lets see some more pics!!
You asked for it, here are a few more. It's been kinda busy around the shop lately so I haven't had much time to work on it.
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Old 03-17-2011, 12:19 PM   #15
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Quote:
Originally Posted by 94 yj
Nice start. If you go the air tank route, I'd figure a drain for condensation like a compressor...but you'd have to protect from damage (sorry I run air tools for a living and water is bad). If you plan on towing with the bumper I'd look into some frame tie-ins for the factory crossmember.

Keep posting pics, looks good.
-John
Thanks John. I was originally thinking of making it into an air tank but I've scrapped that idea. As far as towing, I won't tow anything very heavy. It was more for my hitch rack, but a small pop-up tent trailer in the future.
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Old 04-06-2011, 01:52 AM   #16
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Sorry about the long delay in updates. Here are a couple of pics before I painted it black. I'm going to take a couple more tomorrow and post up.
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Old 04-06-2011, 01:55 AM   #17
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One more pic
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Old 04-07-2011, 06:53 PM   #18
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Here is the finished product... FINALLY!!
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Old 05-02-2011, 11:47 AM   #19
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Subscribed... looks great i'll be copying that pretty much to the T
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Old 05-03-2011, 09:27 PM   #20
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Subscribed... looks great i'll be copying that pretty much to the T
Go for it!! That's a part of the reason I started this thread. Have fun making it and take pics for us!!
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Old 05-04-2011, 01:31 PM   #21
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Great. Are you adding d-rings to it or a hitch?
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Old 05-04-2011, 02:35 PM   #22
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Great. Are you adding d-rings to it or a hitch?
If you had that, I'd buy it!
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Old 05-04-2011, 02:42 PM   #23
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good fabricating there!
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Old 05-04-2011, 04:44 PM   #24
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If you had that, I'd buy it!
Osprey? Like the packs?
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Old 05-04-2011, 07:31 PM   #25
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I was wondering why no d rings or a hitch as well. Nice though.

The only thing I would suggest is maybe a flat plate across the top to slider under the tub between the body mounts. It would make mounting a lot easier and also hide the gap between the sock plate and your new bumper.

Looks great anyway!
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Old 05-05-2011, 08:02 AM   #26
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Osprey? Like the packs?
Osprey like the University of North FL fighting Ospreys! "We will swoop you up!" (really, they say that...). Class of 2002! (man I feel old...)
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Old 05-05-2011, 02:28 PM   #27
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Great. Are you adding d-rings to it or a hitch?
My original intent was to put D-rings and a 2" receiver, but I needed some quick cash unexpectedly so I sold it as last shown for $100. I have more material to build 3 more, and I am gonna put the above items and I'm seriously thinking of adding a set of the 4" 54ct LED lights for aux back-ups that are recess mounted. Hopefully I'll be able to get to work on one for myself (again, haha) and one to sell.
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Old 05-05-2011, 02:29 PM   #28
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good fabricating there!
Thanks, it had been about 15 years since I had done any welding, but it all came back in no time at all.
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Old 05-05-2011, 02:36 PM   #29
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Originally Posted by 95YamJam
The only thing I would suggest is maybe a flat plate across the top to slider under the tub between the body mounts. It would make mounting a lot easier and also hide the gap between the sock plate and your new bumper.

Looks great anyway!
I have not been a big fan of bumpers that are tight to the rear frame rail for mounting. A couple reasons are because when in the mud, it'll get in between and may be a rust area in no time. Another reason was to give just a bit more space in case of an accident. I'd rather have a few inches extra (I know, wouldn't we all!!) And I've been tinkering around your suggestion of using a piece of angle to use as another bolt point via the body mounts. I'll see where that leads me.
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Old 05-05-2011, 03:32 PM   #30
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Originally Posted by ospreyguy

Osprey like the University of North FL fighting Ospreys! "We will swoop you up!" (really, they say that...). Class of 2002! (man I feel old...)
Oh. Nevermind then haha

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