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Old 05-02-2012, 10:21 PM   #1
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My JK Front & Rear Bumper Build Pics

Well I finally got around to building my bumpers. Any comments good or bad are welcome. I don't have all the fancy tools or shop, but make due & am thankful for what I do have.

I built the rear bumper first. Took the better part of 1 day.
Went out & bought some 6 inch channel, (1/4" thick) for both bumpers.
The rear is 52" wide.



Did all of the drilling with a hand drill. All holes are 1/2".





Had to cut up the hitch so I could weld it up to the bumper.



Here it is in my fancy paint booth. It's funny, I was using these trash cans as saw horses while welding & had a pretty big fire. Took me a while to figure it out with the welding hood on, lol.







I cut up a huge Allen Wrench & welded pieces to the edges of the bumper to prevent the Hi-Lift from sliding out on me. Works really well. The stock bumper is 100% plastic. Really couldn't believe there wasn't at least a little sheet metal or tin of some sort in it. Nice to be able to jack up the Jeep by the bumper. It didn't move an inch.




I used 3" channel to attach the bumper to the frame. All hardware was grade 8, 1/2" bolts. Also, two of the D-Ring mounting bolts went all of the way through the frame. The rear of the hitch was also attatched to the frame, using existing holes, with 2 more 1/2" bolts. So in all, eight, 1/2 inch bolts holding this bumper to the frame of the Jeep. Overkill I know, lol.




Finished product, with my slider/spare tire support in place.






I'll post up the front winch bumper build shortly. Thanks for looking!!

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Old 05-02-2012, 10:27 PM   #2
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Looking good!!!

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Old 05-02-2012, 10:35 PM   #3
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Looking good!!!
Thanks Ken!!
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Old 05-02-2012, 10:37 PM   #4
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looks good. I like your idea with the Allen wrenches
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Old 05-02-2012, 11:09 PM   #5
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On to the front Bumper. The fact that i wanted to make it a winch bumper made the project much more difficult. Partly due to the fact that I was not going to be as happy if my winch blocked a significant portion of the radiator. Trying to keep the winch low & the bumper high & as close to the radiator as possible is no easy task.

The end results fetched me pleasing results. My bumper offers 1/2" more ground clearance and sticks out about the same.

I started with the same 6" channel, 1/4" thick. Wanted to carry out the same theme of the rear that I built a few days earlier. Theme= Plain, bold, strong, kinda ugly.....CHEAP!!!

Since it is a front bumper I decided to dress it up a bit so I cut the corners off. Here you can see the big azz Allen Wrench I welded to the bottom to prevent the Hi-Lift from sliding out.

The 2.5" angle iron you see is what my winch plate is bolted to.





Speaking of winch plates. My neighbor sold me his new SmittyBuilt winch & threw in 2 winch plates. He owned a TJ so I had to modify the winch plate.



Here it is installed.



My drill press, lol.





Here I have it sitting on some blocks. Just cut out the winch line slot.



Here are some 1/4 inch plates I cut out for the push bar to be welded to.



With the push bar.



The D-Ring mounts were a huge concern for me. I have seen many videos where individuals get seriously injured when they fail. I didn't feel safe making my own so I researched until I found these babies.

The plates are a full 1/2" thick. The mounting tabs are 1" thick. When I opened the package my jaw hit the ground. These things are almost too beautiful to put on the front of the Jeep, lol. They come powdercoated & ready to go!!

I don't mean to sound like a salesman, but when I spend my money, order over the web & receive exactly what was promised for a fair price, I get a tad bit excited.






The tabs were keyed into the the plates & welded on the back side as well. Super super strong.



I purchased them from Cutthroat 4x4. Laura & Don were a joy to deal with. Very nice people. They will customize too!!!

Here's a link to Cutthroat4x4: Cutthroat 4x4

More pics coming.
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Old 05-02-2012, 11:12 PM   #6
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looks good. I like your idea with the Allen wrenches
Thanks Zack! I was going to just use solid rod, but I thought the octagon would look good on there.
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Old 05-02-2012, 11:23 PM   #7
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Here we are priming at midnight!








Getting ready for the D-ring mounts that i love so much! There are these 8 bolts, plus 4 more securing this bumper to the frame. Two at the rear of the winch plate & two bolting down the rear of the push bar mounting plates. Again, overkiil.



Winch in, ready for action!!





Front Yard.



Thanks for lookin!!
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Old 05-02-2012, 11:40 PM   #8
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Looks cool, I would do a little different but it's not mine.. Great work none the less..
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Old 05-02-2012, 11:47 PM   #9
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Looks cool, I would do a little different but it's not mine.. Great work none the less..
Thanks. Ya, I had to make lots of choices during the design process. I really wanted to keep the radiator unobstructed. So i made the push bar high. Also would have sloped it out but I park two cars behind one another in the garage. Couldn't have that thing sticking out. Also my neigbor has a nice pipe bender. He would have bent me a stinger for free. I wanted to stay with the square theme & also build it all myself.


Anywho, thanks for the kind words Sir!!
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Old 05-03-2012, 12:07 AM   #10
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Originally Posted by 07XMan2Door

Thanks. Ya, I had to make lots of choices during the design process. I really wanted to keep the radiator unobstructed. So i made the push bar high. Also would have sloped it out but I park two cars behind one another in the garage. Couldn't have that thing sticking out. Also my neigbor has a nice pipe bender. He would have bent me a stinger for free. I wanted to stay with the square theme & also build it all myself.

Anywho, thanks for the kind words Sir!!
I wanted to build my own instead of spending three times what I spent on mine but I was honestly too afraid it would turn out like crap. Lol, your more man then I am
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Old 05-03-2012, 12:21 AM   #11
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I wanted to build my own instead of spending three times what I spent on mine but I was honestly too afraid it would turn out like crap. Lol, your more man then I am
Ha Ha, I kept the build within my skill level. (straight lines) I have no plasma cutter, I wish. If you don't count the d-ring mounts or d rings. My front cost me 26 bucks & the rear was 18. I only bought the 6 inch channel. All the other metal was scrap on hand. Oh, I gave 300 bucks for the winch & two winch plates. It came with 100' of synthetic line, the hause fairlead, cover & 12' chorded remote.

I'll go to your profile & check out your Jeep
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Old 05-03-2012, 12:32 AM   #12
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Originally Posted by 07XMan2Door

Ha Ha, I kept the build within my skill level. (straight lines) I have no plasma cutter, I wish. If you don't count the d-ring mounts or d rings. My front cost me 26 bucks & the rear was 18. I only bought the 6 inch channel. All the other metal was scrap on hand. Oh, I gave 300 bucks for the winch & two winch plates. It came with 100' of synthetic line, the hause fairlead, cover & 12' chorded remote.

I'll go to your profile & check out your Jeep
That's just it, I work in a machine shop with CNC Mills, plasma cutter, mig, tig (no gas left), arc welders... Just suck at doing this kinda stuff.. Props to you for pulling it off..
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Old 05-03-2012, 12:43 AM   #13
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That's just it, I work in a machine shop with CNC Mills, plasma cutter, mig, tig (no gas left), arc welders... Just suck at doing this kinda stuff.. Props to you for pulling it off..
Again, thanks for the kind words!

I'd be like a kid in a candy store in your shop. Must be awesome to have access to that type of machinery. (And know how to properly use it of course!!)

Tried to see your jeep in your profile. No pic. Got a link to a thread? Saw the smashed front bumper. Did you get it replaced??
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Old 05-03-2012, 01:14 AM   #14
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Good job Bruce!
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Old 05-03-2012, 05:29 AM   #15
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Originally Posted by 07XMan2Door

Again, thanks for the kind words!

I'd be like a kid in a candy store in your shop. Must be awesome to have access to that type of machinery. (And know how to properly use it of course!!)

Tried to see your jeep in your profile. No pic. Got a link to a thread? Saw the smashed front bumper. Did you get it replaced??
It definitely gets me into trouble working there!! But it's nice at times like this past weekend I fixed my wife's Grand Cherokee. She likes her brakes and warped some pretty new rotors so... I turned them down to stop the shimmie shake. Lol.


Attachment 119285

As for my Jeep I ended up getting this and Love it..


Attachment 119286

After playing with y buddies lights before installing them on his Jeep I think I'm going for this look as my next purchase.


Attachment 119287

Ohh yeah I love the over head cranes. Make short work of pulling the motor out of my race car!!


Attachment 119295
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Old 05-03-2012, 06:09 AM   #16
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Also made this for my race car.


Attachment 119298



Attachment 119299


Supports oil pickup tube.
Attachment 119300
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Old 05-03-2012, 08:21 AM   #17
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Bruce, bumpers turned out awesome man!

If I could offer one suggestion as to finishing/blending the corners. A grinder works great for knocking down welds, slag or just rounding a cut. However, a grinding disk does leave some deep nasty gouges in the metal to deal with prior to coating, whether powder coating or painting. A flap style disc works great for rounding off corners and blending welds into the parent material without the deep gouges of a grinding disk. A flap disc also works great to know off the mill scale prior to welding.

Just a tip to save you some grinding time on future projects.

I really like the low, sunken winch mount into the front bumper. I would also like to see a close up of your spare tire support coming off your bumper. That sounds like a good inexpensive way to support those heavy tires and keep from damaging tailgates.

Keep up the good work.

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Old 05-03-2012, 09:39 AM   #18
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Good job Bruce!
Thanks Julie. It was a fun build for sure. Hope all is well with your Fam. Tried to hook up with you in Moab. Called Jeff one night, you guys are always sooooo busy. That's a good thing.
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[QUOTE=Phobos;2330120]It definitely gets me into trouble working there!! But it's nice at times like this past weekend I fixed my wife's Grand Cherokee. She likes her brakes and warped some pretty new rotors so... I turned them down to stop the shimmie shake. Lol.

As for my Jeep I ended up getting this and Love it..

After playing with y buddies lights before installing them on his Jeep I think I'm going for this look as my next purchase.

Ohh yeah I love the over head cranes. Make short work of pulling the motor out of my race car!!

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Originally Posted by Phobos View Post
Also made this for my race car.

Supports oil pickup tube.
Nice Jeep ya got there. I like those lights too. Thinking about the KC Highlights, 130 watt for mine.

So cool you built that support out of a solid block of aluminum. That's better than a piece of artwork in my opinion. Thanks for sharing Bro!!!

Any side view shots of your jeep?
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Old 05-03-2012, 09:58 AM   #19
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Bruce, bumpers turned out awesome man!

If I could offer one suggestion as to finishing/blending the corners. A grinder works great for knocking down welds, slag or just rounding a cut. However, a grinding disk does leave some deep nasty gouges in the metal to deal with prior to coating, whether powder coating or painting. A flap style disc works great for rounding off corners and blending welds into the parent material without the deep gouges of a grinding disk. A flap disc also works great to know off the mill scale prior to welding.

Just a tip to save you some grinding time on future projects.

I really like the low, sunken winch mount into the front bumper. I would also like to see a close up of your spare tire support coming off your bumper. That sounds like a good inexpensive way to support those heavy tires and keep from damaging tailgates.

Keep up the good work.

Mike.
Thanks Mike, that means a lot coming from you. Ya, as far as the finish goes. I actually have some of those flap wheels. I used them a little. I guess getting the mirror finish isn't really my goal. Plus I only have a 4 inch flap wheel. It takes forever to get it purdy. I know I'll be gouging these things up over the years & will just grind & rattle can it back into shape.

I've never seen such quality metal workings like what you did in your bumper build. Simply perfection. I showed my wife & she said. "A dude on the forum built that at his house? Realllllly? Then she looked at me & my bumper & said, Reallllly!!!

Ya, I really wanted to keep the winch low. So many after market bumpers have the winches high. That took some time to figure out how to keep it low & not having the bumper stick out too far. It's much stronger too. The rear of the winch plate is bolted directly to a heavy 2x2 crossmember, not the stock flimsy one.

As far as the rear spare tire support/slider goes, heres a link.
Hitch mounted spare tire support pics...

Thanks again for the kind words Mike!
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Old 05-03-2012, 11:19 AM   #20
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Thanks Mike, that means a lot coming from you. Ya, as far as the finish goes. I actually have some of those flap wheels. I used them a little. I guess getting the mirror finish isn't really my goal. Plus I only have a 4 inch flap wheel. It takes forever to get it purdy. I know I'll be gouging these things up over the years & will just grind & rattle can it back into shape.

I've never seen such quality metal workings like what you did in your bumper build. Simply perfection. I showed my wife & she said. "A dude on the forum built that at his house? Realllllly? Then she looked at me & my bumper & said, Reallllly!!!

Ya, I really wanted to keep the winch low. So many after market bumpers have the winches high. That took some time to figure out how to keep it low & not having the bumper stick out too far. It's much stronger too. The rear of the winch plate is bolted directly to a heavy 2x2 crossmember, not the stock flimsy one.

As far as the rear spare tire support/slider goes, heres a link.
Hitch mounted spare tire support pics...

Thanks again for the kind words Mike!
Thanks Bruce, don't be building me up into something I am not. I am just a mechanic who can't afford all of the off-the-shelf parts so I had to learn to expand my skills into fabrication. I also like to inform others of things that I have had to learn the hard way.

I just checked out your spare tire support build thread, good job and very ingenious my friend.

Mike.
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Old 05-03-2012, 11:29 AM   #21
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Thanks man, that support took some time plan out. The programming got a little trickie for me I hate cutter compensation..


Thanks for the compliments on my Jeep. When I was shopping I fell in love with it as soon as I saw it. Price was good too..

Taken 5 minutes ago. Hope it's what your looking for.


Attachment 119352



Attachment 119353
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Old 05-03-2012, 11:47 AM   #22
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Thanks Bruce, don't be building me up into something I am not. I am just a mechanic who can't afford all of the off-the-shelf parts so I had to learn to expand my skills into fabrication. I also like to inform others of things that I have had to learn the hard way.

I just checked out your spare tire support build thread, good job and very ingenious my friend.

Mike.
Thanks Sir. I takes less than 1 minute to drop the ratchet strap (tied a knot in the end so it is always adjusted perfectly & can't slip out of the ratchet when not in use.) & turn the support down a couple cranks.
Welds got better on the bumper build after I ran to town & got a new bottle, lol. Need to watch gauges more closely. Using 75% Argon.
Ha ha on the building you up comment. Your work speaks volumes!

Quote:
Originally Posted by Phobos View Post
Thanks man, that support took some time plan out. The programming got a little trickie for me I hate cutter compensation..
Thanks for the compliments on my Jeep. When I was shopping I fell in love with it as soon as I saw it. Price was good too..

Taken 5 minutes ago. Hope it's what your looking for.
Looks great Phobos! ! actually love those wheels. If they were 8 inches wide I'd still be rockin mine. (and paying more for tires, lol.)
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Old 05-03-2012, 11:56 PM   #23
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What a stud! Fearless in the face choices and yet you push on. The bumper turned out awesome Bruce! When are you going to start taking orders for others?

I know you saved a ton and you get the satisfaction of knowing you did it yourself, your own design and by your own hands. Really nice work bud!

Now, wrap that winch cable around something and yank on it! I'm sure it will hold up great.

I'm jealous you have the time, tools and know how to tackle a project like that.

Cheers,
Steve
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Old 05-04-2012, 12:26 AM   #24
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What a stud! Fearless in the face choices and yet you push on. The bumper turned out awesome Bruce! When are you going to start taking orders for others?

I know you saved a ton and you get the satisfaction of knowing you did it yourself, your own design and by your own hands. Really nice work bud!

Now, wrap that winch cable around something and yank on it! I'm sure it will hold up great.

I'm jealous you have the time, tools and know how to tackle a project like that.

Cheers,
Steve
Thanks Steve,
The rear was real easy. The front was a bit more difficult.
Ya, I've prolly got less than 40 bucks in the steel for the pair. The D-ring mounts were 80 bucks a pair. Winch I bought used from a neighbor. He never used it once, looks brand new.

Had the jeep in 2 foot snow drifts todays, but noooooooo... couldnt get it stuck

How's life in sunny CA?
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Old 05-04-2012, 09:05 AM   #25
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Sunny So Cal along the beach has been May Gray and 60-65 degrees! Still waiting for the sun to show up. Friends of mine in western New York are having better weather than we are! Sucks but I can't complain about living in San Diego, never, not even after 45 years.

Great looking bumper Bruce!

Take it easy and let's talk soon on the flip side.

Steve
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Old 05-04-2012, 09:12 AM   #26
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Great job
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Old 05-04-2012, 10:28 AM   #27
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Sunny So Cal along the beach has been May Gray and 60-65 degrees! Still waiting for the sun to show up. Friends of mine in western New York are having better weather than we are! Sucks but I can't complain about living in San Diego, never, not even after 45 years.

Great looking bumper Bruce!

Take it easy and let's talk soon on the flip side.

Steve
Ha ha, The Wife & I were peddeling our bikes around the neighborhood yesterday with several others. I said, "Boy, this weather is absolutely perfect, wish it were like this all year long." A buddy replied, "it is, in SAN DIEGO!!!" I think overall weather wise, it must be awesome down there. Speaking of down there. Was your return trip"less eventful" than your trip to Moab?

My wife has never been to the frikin zoo there. I want to get her down there for that and sea world. She absolutely loves animals. Hmmmmmm.

Thanks again for the kind words Sir!

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Great job
Thanks Ken!
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Old 05-06-2012, 08:17 PM   #28
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Had several peeps asking to see a side view of the bvumpers...



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Old 05-07-2012, 10:56 PM   #29
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Looks good man. Im glade to see you reinforced were it mounts on the rear frame. Overkill is an underrated achievement. With the winch, rope, front and rear bumper you paid way less then I did for all mine. Great job. Now come with me to moab and lets go test it out this weekend. 5/12-5/13, not sure what trails Im doing but Im due for some wheeling, I was thoroughly disappointing for EJS I want some redemption.
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Old 05-08-2012, 09:42 PM   #30
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Looks good man. Im glade to see you reinforced were it mounts on the rear frame. Overkill is an underrated achievement. With the winch, rope, front and rear bumper you paid way less then I did for all mine. Great job. Now come with me to moab and lets go test it out this weekend. 5/12-5/13, not sure what trails Im doing but Im due for some wheeling, I was thoroughly disappointing for EJS I want some redemption.

Thanks Chad.
It's funny, I thought of the statement in your sig about being overkill. Couldn't remember whos sig it was. lol. I like overkill. always have.

I work the 13th & promised Momma we take the KTM's out on Sat, so I'll have to pass on the invite even tho it sounds like a blast for sure.

Who are you going down to Moab with? Any new additions to Sheila?

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