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Old 11-10-2009, 09:50 PM   #1
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Modded/New bumper

Had a Jeeperman light hoop on my Jeeperman bumper. It got bent back pretty good (bolt on) when I had an incident offroad. See for yourself.





Also cost me part of my Warn winch housing and motor housing and a set of IPF offroad lights.

Well, I've gotten the IPF's fixed (IPF has replacement housings) and the original lights are about to be back in action. Fixed the winch and motor housings. So now it was time to get my bumper back to snuff, but a bit stronger.

Tossed about a few ideas and I wanted to go with a grill hoop with stinger setup.

Here's how it progressed...



My son doing some bending:



Mock fitting


A bit of cutting here and there

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Old 11-10-2009, 09:50 PM   #2
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Hoop and Stinger welded in.




Reinforcement plate for the grill hoop...


The support brace between the grill and stinger.


Bumper back on temporarily to get it home and primed and painted.


And with some paint...


The welds actually look a lot better than the shadows in this pic shows. Are they perfect? Not all, but a lot of them look REALLY good. Getting welds into those angled spots proved a bit challenging. All of us involved are new to welding, and it shows sometimes.

I have a few more layers to put on since I sanded down some rough spots where rocks had tried to eat it, so the whole bumper got primed with Rustoleum primer and now being covered with Rustoleum Satin black. May shoot it with a few layers of clear to give it a shine comparable to my other armor... still undecided though.

All in all, a GREAT learning experience for all of us.

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Old 11-10-2009, 09:57 PM   #3
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make me one please...




looks great btw
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Old 11-10-2009, 10:46 PM   #4
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That bad boy won't go anywhere....I pitty the fool tree that gets in your way next time!!!
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Old 11-10-2009, 10:57 PM   #5
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I really don't want to test it to find out.

I've seen similar designs from Genright and other makes, but we had to make some adjustments. The winch plate bent back a bit too, so we had to allow for that. We added the 1/4" plate to reinforce where it would mount. Part of the Jeeperman mount system has extra holes for YJ's and they're ovaled out. I didn't use those, so we plug welded em. With the 1/4" plate on top, it really reinforces for added protection. With the stinger, I didn't want it flopping back, so we did the cross bars. I didn't want to go too high on the grill hoop to use physics to have a solid base. If I ran them too high up, the steep angle would not be as strong. Halfway up (approximately) was a good medium and gave some great looks.
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Old 11-11-2009, 08:54 AM   #6
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Looks really good!!
Now it's time to get a hydraulic bender!!! .... oh, wait, that's what son's are for!! LOL
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Old 11-11-2009, 09:29 AM   #7
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Very Nice !
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Old 11-11-2009, 10:16 AM   #8
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Looks great!
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Old 11-11-2009, 08:59 PM   #9
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That looks really nice. Lets see some more welds. Do you have a notcher or is that what that grinder is for? What size and thickness is that pipe?
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Old 11-11-2009, 09:48 PM   #10
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Looks like shit, you should probably just mail it to me

just kidding, great job on it and that looks sick! I wouldn't mind learning how to weld one myself since I hate the bumper on mine.
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Old 11-11-2009, 11:49 PM   #11
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Nice work! I think you certainly made it better than it was before the "incident"!
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Old 11-12-2009, 08:24 AM   #12
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Quote:
Originally Posted by noljohn View Post
That looks really nice. Lets see some more welds. Do you have a notcher or is that what that grinder is for? What size and thickness is that pipe?
He had a notcher, but we didn't have the right size fitting for the tubing we used. So we used the chop saw to get things close and a grinder to finish it. We have a program that lets you input tube size, thickness, and angle of the intersection, and it'll print out a pattern you transfer to the tube to cut for a precise fit. Part of the issue was getting good fitment for the grille hoop. The way we did the bends, they would attach to the bumper plate in an awkward location. So we 'extended' the plate back to near the sway bar mounts with 1/4" plate on top of the existing plate, which is also strengthened with new Grade 8 bolts to hold it all on. No oval holes this time, like the Jeeperman bumper/hoop plate had. Perfectly lined up 1/2" hole fits the bolt perfectly. The grille had additional fitment issues since the winch plate got bent a tiny bit after the bump, so the angle got even MORE complex. We set it with about a 5 degree rake backwards so the hoop wouldn't be sticking TOO far out in front of the grille. The welds for the hoop and stinger were no problem.

As it turned out, the sway bar bolts are NOT in the way at all, and the bumper/hoop setup allows a wrench to reach every necessary bolt.

IIRC it is 1.75" DOM tubing that we used. I'll have to double check the thickness. I'm thinking .120

Even with all of that, we didn't get it perfect. We had a few gaps that he filled with tack welds then went over them again for the permanent welds. The flat welds came out GREAT as you could see by that plate. The ones around the tubing have excellent penetration, but they are not the prettiest. They do go through and they are solid. If we had had the right notching bit, it would have been a MUCH better fit, and hence, better welds. But they're solid and I'm not complaining. With the painting, you don't see it much at all and the 'uglier' parts of the welds actually face towards the rear anyway. Eh, it's homemade, so even if it isn't perfect, we built it, and it will stand up to the abuse I (try not to) give it.
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Old 11-12-2009, 08:27 AM   #13
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Here are a couple of quick pics I put on after paint... It is still curing in spots, so I'm waiting to reinstall the lights and winch.





I really need to get a profile shot of it.
HOPEFULLY, I'll have a chance to get everything reinstalled this weekend. The way it is set up, I may not be reusing the Hellas I have on my windshield. I have replaced my IPFs that broke and have another set for the windshield. Unless I can find a location for the Hella's on the new setup, they'll be either used as rocklights somewhere or they'll be put on a shelf. The stock OEM fogs are already ON the shelf.
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Old 11-12-2009, 11:17 AM   #14
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Nice work, looks good!
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Old 11-12-2009, 11:24 AM   #15
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It's beautiful, almost made me cry...
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Old 11-12-2009, 07:22 PM   #16
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erickpl thanks for the tech info I'm a hobby welder so I know the work that goes into something like that. Your welds that I saw looked great. I'm in the process of making a roof rack for mine I'll post pictures when I get a little further along.
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Old 11-16-2009, 09:18 AM   #17
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Probably the final pics I'll post in here of this unless somebody wants more details or has questions.









Lights are attached, but not connected yet. Picked up new connectors to replace the ones that look a little rough. The old IPF's will be on the bumper and the new IPF with stoneguards will go on the windshield (the guards will reduce the side glare like I have right now with the Hella's...





I tried to position the OEM fogs around the setup and didn't really find a place where the lights would look good and be functional. If I mount them higher on the cross bar, they are in the way of the headlights. No bueno. If I put them on the stinger, I'll have to rename Kermit to Mickey Mouse, and they'll block my view on the trail and road.
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Old 11-16-2009, 10:18 AM   #18
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Very sweet, I would be worried about those lower lamps getting smashed, but like you said idk where else you would put them...Unless you can draw them back a couple inches.

Now you can fab up a new RF fender
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Old 11-16-2009, 10:19 AM   #19
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I like it. Looks good. You did an awesome job on it.
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Old 11-16-2009, 11:20 AM   #20
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Quote:
Originally Posted by mudslinger150 View Post
Very sweet, I would be worried about those lower lamps getting smashed, but like you said idk where else you would put them...Unless you can draw them back a couple inches.

Now you can fab up a new RF fender
I have a new passenger fender - I got it for free along with a hood and newer style cowl for the air vent.

My fogs took a slight hit with the old style hoop. These ones I configured so that they should lay back if hit, but stay still while driving. I just know up on top of the light hoop, they'd be sitting ducks. With the tube and reinforcement I have on there, I feel pretty comfortable with where they are at. It took 6 years to break any light I had there, so I feel I'm doing okay.

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