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Old 05-08-2013, 10:03 PM   #1
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Started back bumper/roof rack project

After literally months of delay, I finally started the fabrication on my back bumper and canoe/kayak rack. To back up a little, last fall I built the front bumper, which was originally going to be integrated into the rack, but the design has changed about 6 times since then

To begin the back, I took a piece of 3/16" plate and had it sheared and broke to the dimensions I needed. The steel was free (it's good to have friends!) and the breaks cost me $20 at a local steel shop:

After marking center I cut down at a 30* angle, and found that Bud Lite and steel fab don't mix, so I had to weld a piece back on, lol . The added back piece can be seen on the left end here:

To mount it, I'm going to cut and tap 2 square plates and weld them to the back of the frame, and mount the bumper using 8 bolts to match the front.
For the front of the rack, I'm just basically using the same design as a light bar. I'll bend a piece of 1" schedule 40 pipe to clear the roof by 2" and mount to the windshield brackets here:


I pulled the bracket to start building the mounts. It looks like its going to be a bit tricky to get it to flow with the body of the jeep.
For the rear of the rack, I found these tapped holes in the frame:

I'm going to build mounts to bolt on there, then bend pipe to come around the body and tie that into the rear bumper by bringing the bumper around to meet it. That will leave me a small, unobtrusive place to mount the upper part of the rack, which I'll leave off when not in use. As the project progresses, I'll update with pics! I was going to powder coat it all when finished, but I'm not sure ill ever be able to grind my screw-up on the bumper smooth enough to make it invisible, so I may do a little bondo work and bed-line it all. Still undecided on that. When finished, I should have less than 100 bux in the whole project!

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Old 05-08-2013, 10:39 PM   #2
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The best part of the project: my non-jeeper buddy who is loaning me his shop to work in shakes his head and said "I admire your willingness to tear apart and rebuild a brand new vehicle like its a '79 CJ" lol

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Old 05-08-2013, 10:50 PM   #3
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Old 05-09-2013, 05:34 AM   #4
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Quote:
Originally Posted by ip0vv3r View Post
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Old 05-10-2013, 12:47 AM   #5
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I got to do a little more tonight. After taking about 67 measurements, I figured out that the frame on the drivers side was about 1/8" longer than the other side. Some quick work with a grinder, and I was ready to tack the plates I'll be mounting the bumper to on the frame:


With the basic shape of the bumper ready to go we went to work on the endcaps, so it went from this:

To this:


You can see right under the license plate where we had to add a small curved piece to make the bumper flow with the body of the jeep. After getting it all tacked into place I pulled the bumper off again to weld everything up...

What I have so far, mounted back up:

I still have to build the notch for the spare to fit. At the rate I'm going it will probably take an entire evening...
Bonus! My buddy had my recovery points laser cut and brought them home so they'll get welded on the next time I get to work on it..

I still have a way to go, but its coming along. Tomorrow I'll spend a couple of hours grinding out the big gnarly welds I make
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Old 05-21-2013, 12:49 PM   #6
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Got the bumper and rear part of the canoe rack finished, I just need to get them powdercoated. Here's the bumper just before installing...

For the rack, I built a receiver that mounts to the frame using the pre tapped holes that the factory bumper bolted to

Then, we bent a piece of 1" schedule 40 to follow the body lines as closely as possible..

And here's what it looks like with everything in place:


The rack can be taken off easily by unpinning it and simply lifting it off of the receivers, and the receivers detatch with 2 bolts each. Most likely, they'll hardly ever come off but its nice to make a mod that can be removed so easily. I can't wait to get the powder coating done and see it finished! Next up, front rack. I'll build it exactly like a light bar, out of the same pipe..
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Old 05-21-2013, 01:07 PM   #7
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I have legitimate envy for your fabricating skills
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Old 05-21-2013, 02:49 PM   #8
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all I can say is WOW!! that's some great work right there!
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Old 05-21-2013, 09:33 PM   #9
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Thanks! I'm getting better
It helps to have a really good fabricator to help with the technical parts
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Old 06-15-2013, 06:35 PM   #10
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Checked out your work, good stuff there man! Great work.

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