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Old 05-28-2011, 11:13 AM   #1
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Started on my bumpers- Front done

OK... I know... IM ALL STOCK!!! But I have to start somewhere!

So I grabbed some .120 wall 2x6 stock and designed what I wanted for the front... light, but strong... and a bit of appeal with GOOD tow points....

After design and template for angles and dimensions.... here is the first few cuts....


After massaging the metal into position... I tacked it all up....



In this pic... I already have it completed and test-fit... Sorry I didn't snap any pics of the 1" tow points with 7/8" holes or the relief cuts on the ends where it angles back.

The real support of this bumper is the .25" 3x3 angle on top (makes the top a full 5") and the .25" 2x2 angle on the bottom which spans the width of the bumper. The tow points follow through the bumper and the 'strongback' and are fully welded inline with the inside framerail.


And after I finished massaging the test fit... I cleaned it up nice and gave it a nice coating.....



Fabrication is SOOOO much fun!!!!



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4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
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Old 05-28-2011, 11:17 AM   #2
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Looks great...nice fab work!

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Old 05-28-2011, 11:36 AM   #3
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Very nice!
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Old 05-28-2011, 11:48 AM   #4
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Looks good!
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Old 05-28-2011, 12:04 PM   #5
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Outstanding!
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Old 05-28-2011, 12:08 PM   #6
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Looks great. A little too wide for me though.
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Old 05-28-2011, 01:52 PM   #7
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Thanks all!!! The rear I started on yesterday.....

Quote:
Originally Posted by nick50471 View Post
Looks great. A little too wide for me though.

The pics are a bit deceiving on the width.... the ends are flush with the fenders... NOT with the flares...... since my TJ will be about a 75/25 split between DD and trails... I wanted a bit of fender protection..

I may redesign something a bit 'smaller' in the future... not sure yet....
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~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
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Old 05-28-2011, 03:14 PM   #8
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Looks great! I just got my front one half finished. I went simpler than you did though but mine is .250 thick.
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Old 05-28-2011, 03:18 PM   #9
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Quote:
Originally Posted by 95YamJam
Looks great! I just got my front one half finished. I went simpler than you did though but mine is .250 thick.
Cool! I was gonna go .250. But I figured I would save the weight for the 12.5k winch. 
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~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
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Old 05-28-2011, 03:36 PM   #10
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That's a lot of winch for a Jeep.
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YOU ONLY NEED TWO TOOLS IN LIFE - WD-40 AND DUCT TAPE. IF IT DOESN'T MOVE AND SHOULD, USE THE WD-40. IF IT SHOULDN'T MOVE AND DOES, USE THE DUCT TAPE.

IF YOU CAN'T FIX IT WITH A HAMMER, YOU'VE GOT AN ELECTRICAL PROBLEM.
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Old 05-28-2011, 04:12 PM   #11
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Quote:
Originally Posted by Mortalis5509 View Post
That's a lot of winch for a Jeep.
I know.....
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~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
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Old 05-28-2011, 04:31 PM   #12
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Quote:
Originally Posted by TnDz TJ View Post
I know.....
lol....nice looking bumper btw
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Go DAWGS!!

YOU ONLY NEED TWO TOOLS IN LIFE - WD-40 AND DUCT TAPE. IF IT DOESN'T MOVE AND SHOULD, USE THE WD-40. IF IT SHOULDN'T MOVE AND DOES, USE THE DUCT TAPE.

IF YOU CAN'T FIX IT WITH A HAMMER, YOU'VE GOT AN ELECTRICAL PROBLEM.
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Old 05-28-2011, 05:56 PM   #13
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Quote:
Originally Posted by Mortalis5509

lol....nice looking bumper btw
Lol! The way I see it... Go big or go home. Can't have too much winch.....can u?
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~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
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Old 05-30-2011, 01:56 PM   #14
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Very pretty. What did you paint it with? Nice design but still clean.
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Old 05-30-2011, 05:13 PM   #15
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Very pretty. What did you paint it with? Nice design but still clean.
Thanks! That is EXACTLY what I was going for! Not over the top and VERY useful!

I am a FIRM believer in Plasti-Dip. Some won't go near it. I LOVE IT!!! If you do it right from start to finish... you cannot mess this up.

I used etching primer for starters. Then I used 220 wet sand, then primed again. Shot a good 2 coats of satin black. Let it dry for around 30 minutes. Then I put a good even coat of Plasti-Dip ( aerosol can) on the entire bumper. Let is sit for 30 more minutes. I then began to lightly dust the bumper about 5-6 times every 15-20 minutes to 'build' a slight texture.

Now its a satin/texture finish. If you are wondering about chipping... lol... I did my 07 Jetta Wolfsburg chrome grille 9 month ago and no chips with 7000 highway miles over Donner Pass from Reno to Sac through the winter. I just got back from Sac with the TJ and not a chip to be had.... just a few bug splatters.... speed limit all the way.... lol!!!
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~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
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Old 06-18-2011, 09:43 AM   #16
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it looks amazing where can i place my order for one?
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Old 06-23-2011, 10:23 PM   #17
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Originally Posted by KKhamesi View Post
it looks amazing where can i place my order for one?

LOL!!! Sorry.... I can't start making parts for everyone.... I am honored that you would want one..... THANKS!!!

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~Todd~ 2004 X 4.0 5 speed---SOLD
4" Lift, 4.56's, 33" Duratracs on M/T Classics
RR SYE, Tatton CV, MML, BL, TT, Dynomax Exhaust
Hella Lighting: Driving, Fogs and H4 E-Codes
NOPE! ... and NEVER will be...
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