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Old 10-15-2012, 07:15 PM   #1
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custom fabricated bumpers

Just got my first Tj 05 and I want to start it by fabricating my front bumper and need some ideas or cad drawings. Anyone have any or know where to get any??

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Old 10-15-2012, 08:16 PM   #2
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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.....



and now after winch and lighting...lol... and a few other mods as well...


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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
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Old 10-15-2012, 08:16 PM   #3
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the rear...

.25" wall 3x4 tubing for the main body at 60" wide. Yeah... I know... it's wide, but I wanted a bit of extension on each corner for protection.

The 1" thick tow points drilled to 7/8" eyelets go completely through the entire bumper and welded under the pads 100%

The mounts are .25" plate material backed by 4x4x.25" pads backing the bumper.


The receiver is custom by me and clearance through the back. the recessed 7 -way RV connector was the add-on for future tows of a boat or small trailer.

and freshened up with paint and mounted for now while I go into design on the swing-away carrier.

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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 10-15-2012, 08:25 PM   #4
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Then build a swing-away...

The pivot point of my swing away is made of SS that I cut down to fit some Timken Bearings and Races for a 1.25" shaft.


End caps from mild steel stock and cut to accept shims to tighten bearings for pre-load once all is mounted on the swing-away.


I decided to go with 1/8" wall 2x2 tubing for strength and weight... I knew it was going to be heavy. The locking pin is spring loaded and ramps up the SS tab with recess to accommodate the 1/2" lock pin.




The latch is surprising small for the amount of weight it holds. This is a De Sta Co 344 vertical hook latch clamp which will hold around 2000 lbs. I trust them since we use this style clamp at work on a lot of machinery guards. This DOES NOT have the built in safety latch... so if you look close, you will see a 5/16" hole just between the allen socket heads. This is for a looped safety pin that captures the handle.



Here is a clearance pic... I have ample room BEHIND the spare for ax, shovel and hi-lift. The tab on top of the receiver is for my CB antenna... once I get a longer cable... it will be there on a spring mount.




I may look like overkill to some, but I wanted it strong. I also have a receiver up top for future fabs, but for now... I got a HF hitch light for a 3rd eye....





I also decided to make it big enough for 35's... IF I ever decide to go that route.... gotta plan ahead!!!



BTW.... since I was doing all this work... I planned ahead for another mod.... Bumper is seals and has fitting for air... I tested it to 175PSI.... no leaks....

and I also utilized the receiver on top with a modified HF cargo carrier....it compliments my Wilderness Rack



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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 10-15-2012, 08:32 PM   #5
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Looks good. I appreciate the ideas. Would it be stong enough if I were to go 3/16" instead of the 1/4"?
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Old 10-15-2012, 08:37 PM   #6
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oh yea..... I went 1/4" wall out back for towing reasons.. and I had the material. Front is .120 wall... plenty strong and tested on rocks and trees a lot,...
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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 10-15-2012, 08:41 PM   #7
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Wow im lovin that swing away. and I really appreciate the detail with pics.
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Old 10-15-2012, 08:49 PM   #8
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So mines simple but strong. I didnt build it, it was on the jeep before I got it. Sorry for lack of pics. Im in south Korea right now so I can upload more. Im adding a stinger to it as soon as I get back to the states.
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Old 10-15-2012, 08:51 PM   #9
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TNDz, everytime I see that work you did I start thinking I need to get me a welder. Then I get sidetracked with another part. Awesome work Devil Dog!
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Old 10-15-2012, 08:58 PM   #10
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I made a custom Stinger with 3/8 2x2 tubing and the main is 3x5 I believe and its also 3/8 thick if I remember right and its actually full pin welded to the stock yj bumber I know tj forum but I figured Id post. Next im tying the top back to the frame I think its strong enough but some members have got me double thinking so im gonna be save instead of sorry!
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Old 10-15-2012, 09:02 PM   #11
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Quote:
Originally Posted by CharTay
I made a custom Stinger with 3/8 2x2 tubing and the main is 3x5 I believe and its also 3/8 thick if I remember right and its actually full pin welded to the stock yj bumber I know tj forum but I figured Id post. Next im tying the top back to the frame I think its strong enough but some members have got me double thinking so im gonna be save instead of sorry!
Sorry applications crashed had some problems with pictures . I seem to of lost the building pictures but heres what I got

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Old 10-15-2012, 09:19 PM   #12
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Quote:
Originally Posted by BLK00TJ View Post
TNDz, everytime I see that work you did I start thinking I need to get me a welder. Then I get sidetracked with another part. Awesome work Devil Dog!
Thanks.... NOW BUY A WELDER ALREADY!!!! 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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