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Old 02-14-2013, 10:17 AM   #1
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Join Date: Jan 2013
Location: Austin, TX
Posts: 831
TJ Bumper on a YJ + Fog Light Brackets

My white YJ originally had chrome bumpers, etc, which didn't look great to me.



I found a stock TJ bumper and bull bar on Craigslist at a good price and modded it to fit. None of this is revolutionary, but I thought I'd share it here as it might give others some ideas.

Detailed pictures of the bumper mods coming soon, but here's one showing the install.



The mods to make the TJ bumper fit on my YJ:
- Change the upper and lower mounting holes in the bumpers to slots to match the different spacing in the YJ frame
- Cut clearance for the shackles on both sides
- Drill a new upper mounting hole in the frame.
- Drill holes for the towing brackets (specific to my situation)
- Drill and tap holes for mounting the license plate (required in Texas, unfortunately) This was specific for me - whoever originally installed the towing brackets welded a piece of 3/8" steel between the frame that interfered with the stock license plate nylon nuts and screws.

Still to do:
- Make a new frame filler out of 1/16" thick aluminum diamond plate (have the material, and will make this weekend). The old plastic filler was too deep to fit under the TJ Bumper.
- Add stock TJ Tow Hooks (ordered from a forum for sale post)
- Replace all hardware with Grade 8 bolts (ordered from eBay)
- Paint everything

I wanted to add fog lights before painting everything, so I didn't drill holes into a newly painted bumper.

I picked up a cheap set of lights from Walmart for $20. Yes, Walmart.

Here's the package:


They seem okay. 55W each. The included wiring is useless - undersized and didn't come with a relay. I'll fix the wiring later.

I started mounting them in the stock TJ foglight mounting hole, but wasn't happy with them. They sat up too high and way too far forward.





Using a hacksaw, vise and 5lb sledge hammper, I made a pair of steel brackets to move the lights down and back behind the front face of the bumper.




Installed:






I'm happy with the final placement.

Some other random notes:
1) Grade 8 hardware is a pain to find, and somewhat expensive. But I want to attend a Jeep Jamboree at some point, and they require Grade 8 bolts on the tow hooks. And it's just a good idea. Ending up purchasing them on eBay.
2) One of the reviews for the foglights state that they won't stay in position. Based on the design, I can see how that could easily happen. I am planning on putting a little black RTV on the bracket faces to help prevent this.
3) My YJ didn't come with stock fog lights, so I have to add all the wiring and relay. I bought a factory fog light switch to make it look "stock" at the dash. There are many posts here on wiring foglights - I won't repeat it here!
4) I would love to spend $150 on some nice Hella lights, but there's other things I want to buy for the Jeep. Saving $130 right now is more important, and I think my brackets and wiring will be compatible with almost any other light that I would want to install.

I'll get some shots of the bumper mods when I remove it for paint.

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