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Custom Bumper Build

4K views 35 replies 14 participants last post by  Chris.gixxer 
#1 ·
Here's a little project I've been working on. It's coming along well, but still a lot of work to do.
 

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#3 ·
I'll keep posting as I go. I started working on the internal bracing tonight, will have to get some more material to French in the fog lights. I think the progress will slow down now.

Thanks for the comments. I think quite a bit of luck plays in there too.
 
#5 ·
This weekend I worked on the fog light mounts. Getting the circles cut out on the bumper and figuring out how to cut the right angle in the pipe proved to be quite challenging. I think it should well up well though.



Bumper Machine Vehicle Automotive exterior Car




Metal




Product Automotive exterior Bumper Auto part Steel



After I had them tacked in, I made lots of tacks in the inside and started welding the seams



Water Floor
 
#8 ·
After having to get the tubing bent somewhere else, and lots of head scratching to get the angle right, the bar has been attached. I also got the mounting plates welded in.

Land vehicle Vehicle Car Jeep Automotive tire


Now, I just have to add the d-ring hangers and put the bottom plate in for the winch to be mounted inside.
 
#10 ·
After having to get the tubing bent somewhere else, and lots of head scratching to get the angle right, the bar has been attached. I also got the mounting plates welded in. Now, I just have to add the d-ring hangers and put the bottom plate in for the winch to be mounted inside.
Incredible work man. Well done. Can't wait to see the finished product.
 
#18 ·
The winch is mounted and everything ready to mount for testing.

Land vehicle Vehicle Car Tire Automotive tire


I found a tree on some flat ground and tested the winch out... Nothing broke! Success!

I have a few thing to tweak and adjust, but it's all minor. Primer and paint will happen as soon as we get some warmer weather.
 
#20 ·
Haha! I got a brand new one for Christmas, if say it's broken in now. Definitely went through my fair share of grinding and flapper discs! I could have avoided a lot of that if I had someone bend and brake the center section, but I wanted to do everything myself.
 
#27 ·
Thanks!


Poison Spyder who? Great job! Wish I had the knowledge and tools to produce something like that. Maybe not , I think my wife would be giving me an earful every time I went into the garage
Knowledge probably isn't as necessary as the tools, haha. I think I posted earlier in the thread, maybe in another thread, but... Had I bought front bumper, sliders, and a rear bumper, I would have had more invested than I will buying steel, a welder, cutting torch and bottles.

You usually can't hear that mouthful if the grinder is running ;) And you can always use the "look how much money I am saving" line. Build her something nice in the process.
 
#24 ·
First let me say this looks great. As others have stated I wish I had the skill and tools to do work like that. Maybe someday -

Second I currently have never had a winch so please understand that I am completely ignorant on this topic. I am thinking about getting a new front bumper with winch so I am curious about your mount. I see that your winch is completely enclosed on top. Is this desirable? I can see where having it enclosed is good for weather/theft protection, but is this a problem when using it on the trail?
 
#25 ·
First let me say this looks great. As others have stated I wish I had the skill and tools to do work like that. Maybe someday - Second I currently have never had a winch so please understand that I am completely ignorant on this topic. I am thinking about getting a new front bumper with winch so I am curious about your mount. I see that your winch is completely enclosed on top. Is this desirable? I can see where having it enclosed is good for weather/theft protection, but is this a problem when using it on the trail?
There are a few reasons I chose to hide it completely. I loved the look of the Poison Spyder Brawler Lite front bumper, that's the bumper I modeled after, but I didn't like the winch mounted on top because I didn't like how it blocked the radiator. I also liked how clean the top of the bumper looked with it enclosed as I was putting it all together. I don't intend to use my winch often, with that said, if I did have those intentions I would have either left it open, or made a removable plate to access it. If you look closely, you can see the clutch lever coming out the top of the bumper to engage and disengage the winch, so it will function without any complications mounted inside. In the event it needs to be serviced or accessed for any other reason, the whole bumper will have to come off.

So, in short, I favored aesthetics over function based on my usage. Will it function fine on the trail? Absolutely! Is this the majorities idea of what is most desirable? Probably not. There is also no way to steal that winch without taking the bumper completely off, or cutting it out. And taking the 2 inside bumper mounting bolts off on both sides is a royal pain... Ask me how I know!

It was also very difficult making the winch fit inside and getting everything lined up and hooked up. Lots of finagling, head scratching, measuring and re-measuring.
 
#34 ·
Thanks again for all the compliments! There's no way I could sell that bumper for a price anyone would be willing to pay.

I finally got it painted and gathered up all the parts to finish it out. I mounted it on the new Jeep last night.



Land vehicle Vehicle Car Jeep Automotive tire


I'll try to get some better pictures when I have some time. You might also notice the brand new BFG AT KO2s on the Jeep. 285/70r17, RK leveling coils will be on the way soon.
 
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