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-   -   Rear Bumper Write-up (PIC HEAVY!!!) (http://www.wranglerforum.com/f105/rear-bumper-write-up-pic-heavy-5892.html)

NWilhelm 02-12-2007 09:21 PM

Rear Bumper Write-up (PIC HEAVY!!!)
 
Here is the write up for a pair of rear bumpers that myself and a friend made a while ago. This is a follow up on the "Rear Bumper Project."

First we started with a trip to the local steel supplier to pick up the supplies:


heres a list of materials:
2"x4"x1/4" wall rectangular stock 55" long (can sub thinner material if you like but I like it beefy!)
approx 7" length of 2 1/2"x2 1/2"x1/4" wall stock for receiver (can sub a store bought receiver tube.. Northern has one for like $10)
approx 7" of 2 1/2"x1/4" thick flat stock for chain plate
approx 6" length of 3"x1/4" wall square stock (for mounting legs and receiver lip)
approx 18" of 3"x3/8" thick flat stock cut in half for the bumper mounting flanges
approx 18" of 2"x1/4" thick flat stock for bumper end caps
approx one foot of 2"x3/4" thick flat stock for clevis mounts
...and a bit of expanded metal to make a logo (we are dorks...but my friend has other stuff he can use the logo for.)

(everything is x2 btw)

we cut everything up and laid it out.

http://i36.photobucket.com/albums/e2...9/IMG_0149.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0150.jpg

Cutting

http://i36.photobucket.com/albums/e2...9/IMG_0152.jpg

Me doin the dirty work.

http://i36.photobucket.com/albums/e2...9/IMG_0154.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0156.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0155.jpg

Both hard at work

http://i36.photobucket.com/albums/e2...9/IMG_0158.jpg

Drilling the mounting brackets

http://i36.photobucket.com/albums/e2...9/IMG_0159.jpg

Yes it's a two man job...

http://i36.photobucket.com/albums/e2...9/IMG_0161.jpg

Driver's Side bracket all "mounted" up

http://i36.photobucket.com/albums/e2...9/IMG_0165.jpg

NWilhelm 02-12-2007 09:21 PM

Passanger side's a bit easier

http://i36.photobucket.com/albums/e2...9/IMG_0170.jpg

Lil bit rusty...

http://i36.photobucket.com/albums/e2...9/IMG_0166.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0169.jpg

Holes all the way through for the shackel mounts and reveiver hitch

http://i36.photobucket.com/albums/e2...9/IMG_0167.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0168.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0171.jpg

Day two begins

http://i36.photobucket.com/albums/e2...9/IMG_0173.jpg

Just chillin'

http://i36.photobucket.com/albums/e2...9/IMG_0174.jpg

Kinda starting to take shape

http://i36.photobucket.com/albums/e2...9/IMG_0175.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0178.jpg

NWilhelm 02-12-2007 09:22 PM

Tacked in place

http://i36.photobucket.com/albums/e2...9/IMG_0179.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0181.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0184.jpg

One's almost done now on to #2

http://i36.photobucket.com/albums/e2...9/IMG_0190.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0191.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0192.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0194.jpg

Chain Plate and Hitch

http://i36.photobucket.com/albums/e2...9/IMG_0195.jpg

Hitch lip and end caps

http://i36.photobucket.com/albums/e2...9/IMG_0196.jpg

Just look at those welds

http://i36.photobucket.com/albums/e2...9/IMG_0197.jpg

NWilhelm 02-12-2007 09:22 PM

http://i36.photobucket.com/albums/e2...9/IMG_0198.jpg

Drilling the shackels was a B****

http://i36.photobucket.com/albums/e2...9/IMG_0199.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0203.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0204.jpg

Ends tacked on

http://i36.photobucket.com/albums/e2...9/IMG_0206.jpg

Its getting there...

http://i36.photobucket.com/albums/e2...9/IMG_0207.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0208.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0210.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0213.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0214.jpg

NWilhelm 02-12-2007 09:23 PM

Friend's lil brother actually helping out

http://i36.photobucket.com/albums/e2...9/IMG_0218.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0219.jpg

Cleanin it up

http://i36.photobucket.com/albums/e2...9/IMG_0223.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0224.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0225.jpg

MmMmMm Bare Steel

http://i36.photobucket.com/albums/e2...9/IMG_0227.jpg

Primer...

http://i36.photobucket.com/albums/e2...9/IMG_0228.jpg

http://i36.photobucket.com/albums/e2...9/IMG_0229.jpg

Doesn't it look good?

http://i36.photobucket.com/albums/e2...9/P1000103.jpg

http://i36.photobucket.com/albums/e2...9/P1000102.jpg

NWilhelm 02-12-2007 09:23 PM

http://i36.photobucket.com/albums/e2...9/P1000104.jpg

http://i36.photobucket.com/albums/e2...9/P1000105.jpg

http://i36.photobucket.com/albums/e2...9/P1000106.jpg

http://i36.photobucket.com/albums/e2...P1000107-1.jpg

And #2 (which we sold)

http://i36.photobucket.com/albums/e2...Untitled-1.jpg

Thanks for lookin through. Sry to all of you DSL guys...


-Nick

Absolute Offroad 02-12-2007 09:36 PM

LOOKS GREAT!!! Thats one of the best thought out, and well built bumpers made at home I have seen!!! Good thoughts on re-inforcement and mounting, all the little details have been thought out!!! Good Job!!


Joe

Scout 02-12-2007 09:55 PM

Looks really great!

amy 02-12-2007 09:59 PM

Great job on the bumper and the write up.

amerijeep 02-12-2007 10:01 PM

Great write-up. I'm going to sticky in General Discussion since this can apply for all models.

naterg 02-12-2007 11:31 PM

That is awesome, I am sending you a PM.

jp'rs_peep'rs 02-13-2007 02:02 PM

As stated in your other posting, very well excuted and attention to detail.

C.

NWilhelm 02-13-2007 07:03 PM

thank you all for the kind words (AND THE STICKY!!!)

if anyone is in the market for a bumper, rack, anything else, just give me a shout and give me an idea of what you are looking for.

thanks

Nick

binaryking 03-01-2007 09:44 AM

Very nice work my friend. Very nice.

Shoughun 04-13-2007 02:26 AM

Great project!!! That's the coolest home made bumper I've ever seen... Nice write up also.. I'm looking forward for my friend's new project in his new jeep, because we will be making a home made bumper and add some mods such as a Jeep bumper end, though we are still in the drawing board... Hope everthing will be just fine..

NWilhelm 04-14-2007 09:18 AM

I'm in the process of designing a swing away to add onto the existing bumper. it should be a fun process.

MR.CLIFFORD 04-14-2007 09:51 AM

Quote:

Originally Posted by NWilhelm (Post 71229)
I'm in the process of designing a swing away to add onto the existing bumper. it should be a fun process.

nick,

Pretty slick fab work. If you add a swing out you may think about some reinforcement to the frame. I put a garvin on my wifes jeep which came with some plate to weld to the frame.

http://i36.photobucket.com/albums/e2...9/P1000102.jpg

It would go in front of your brackets on the opposite side of the cross member and weld directly to the frame. Then just bolt it up. Anything you can do to strengthen the mounting structure would be a plus for adding a larger spare on there. Those stock cross members really are pretty weak.

Excellent job and I commend you are for doing your own work :)

NWilhelm 04-15-2007 11:02 AM

mr. cliff,

yeah i had been taking that into account. I'm not quite sure how i am going to go about beefing it up yet. i may try to make some like PSCs...

https://www.spydercustoms.com/Bumpers/8930_lg.jpg

Unlimited 04-15-2007 11:58 AM

1 Attachment(s)
Have you decided what you are going to do about a pivot for the tire carrier yet? I know a guy that makes them out of a 1750 lb trailer axle. He turns a piece of DOM to fit the bearings and puts a zerk on it. He also mills a really nice cap for the whole thing. (he also makes a 1000 lb version) He gets about $70 + shipping for the bigger one and $45 for the 1k lb version. If you are interested, PM me and I'll send you his info.

I just go mine yesterday, best looking set-up I could find.

Looks like this:

Triple88a 04-15-2007 12:13 PM

Quote:

Originally Posted by NWilhelm (Post 54166)
Thanks for lookin through. Sry to all of you DSL guys...
-Nick

I got DSL it loaded the pics with no problem.. its the K56 modem guys i'm worried about :)

Great job though i'd be interested to see a front bumper also :)

NWilhelm 04-15-2007 04:23 PM

Quote:

Originally Posted by Unlimited (Post 71507)
Have you decided what you are going to do about a pivot for the tire carrier yet? I know a guy that makes them out of a 1750 lb trailer axle. He turns a piece of DOM to fit the bearings and puts a zerk on it. He also mills a really nice cap for the whole thing. (he also makes a 1000 lb version) He gets about $70 + shipping for the bigger one and $45 for the 1k lb version. If you are interested, PM me and I'll send you his info.

I just go mine yesterday, best looking set-up I could find.

I think i have an idea about what i'm gonna do for it. i know a guy who makes them.
his look like this

http://memimage.cardomain.net/member...6_583_full.jpg

http://memimage.cardomain.net/member...6_582_full.jpg

http://memimage.cardomain.net/member...6_584_full.jpg

http://memimage.cardomain.net/member...6_581_full.jpg

we may in fact be talking about the same guy, but i dunno. its hard to tell from the pics.

Quote:

Originally Posted by Triple88a (Post 71511)
I got DSL it loaded the pics with no problem.. its the K56 modem guys i'm worried about :)

Great job though i'd be interested to see a front bumper also :)


I've thought about making a front bumper, but i already have one... now if anyone wants me to try to make one and then sell it i'm up for that. i'd want to have somebody who wanted one before i started making one.

-Nick

Unlimited 04-16-2007 09:39 AM

Quote:

Originally Posted by NWilhelm (Post 71611)
...we may in fact be talking about the same guy, but i dunno. its hard to tell from the pics.

If you are talking about Eddie, then yep, same guy. He's really great to deal with. Is he from your neck of the woods?

NWilhelm 04-18-2007 06:10 PM

Quote:

Originally Posted by Unlimited (Post 71892)
If you are talking about Eddie, then yep, same guy. He's really great to deal with. Is he from your neck of the woods?

yep. Eddie makes some solid stuff. He doesn't live near me, i just know him through JF. i talked to him before i began my bumper for ideas.

J_B 03-02-2008 07:59 AM

I am a certified welder and also a machinist, and I am very impressed. Those looked to be pretty decent beads on the whole thing. What I am more impressed with is that you wore all your safety gear. A lot of people skimp out on it and ends up biting them later. Good build!

NWilhelm 03-03-2008 07:10 AM

Thanks man. I didn't do much of the welding, but i did wear my safety gear;)

rthdtj 03-11-2008 09:11 PM

I have to give this one to you guys.....GREAT JOB ! I appreciate your talent & attention to details & safety. See what you can do with the right tools & good help !

tn-yj 09-30-2008 02:31 PM

Hey man great job! Thats seriously one of the cleanest garage jobs I've seen! One thing I have learned though is when drilling large holes in steel its ALOT easier to step up in small increments. I just noticed that when you were drilling the holes for your clevis you had a large bit on there. I usually do my drilling with a hand held DeWalt and that bad boy will torque your wrist if you arent careful drilling steel. Again great job!

30-284 11-11-2008 11:16 AM

Reviewing this old post I noticed you used seamed tubing for your hitch. I bet that was a bear to get anything in there!

Donn

NETRAracer4636 03-24-2010 02:17 AM

How much did you have invested into materials?

pking911 04-08-2010 01:54 PM

Hey netraracer, this is a pretty old thread. 2/2007 original post. So you may not get the reply you are looking for.

WOW Talk about necroing. I didn't even notice the date of his post.


IGNORE THIS POST!


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