Fabbing a Bumper (pics)

[WheelinJR]

So I've had these 3 sets of bumper brackets I made about a year ago (I didn't even have a Jeep then) and I decided its time to put a set to use.

I am building a light duty front tube bumper to replace my stocker with the goofy pre-runner bar. It isn't the perfect set of brackets for the bumper I'm building, it sticks out far enough for a winch plate but I don't plan on using a winch with this

Done so far List:
1. Cut a 8' chunk of tube
2. Bent it up
3. Bolted my brackets on
4. Tacked my main bar into place

To Do List:
1. 45 cut and cap weld the ends
2. 1" tube from ends of hoop back to mount plate
3. pre-runner style upper hoop of some sort
4. Pair of light tabs
5. find local to machine a nice aluminum skid plate
6. build some sort of cover over "winch plate" area
7. weld it all up
8. off to powdercoat

Yes I know List:
1. Doesn't tie into frame enough...I have a factory towhook kit I am going to use for now, and build tie-in brackets later, then add clevis hooks to the bumper itself.
2. Too wide...I boched my bend lines. I wanted to start the inner bends sooner, and have the overall width end up so that the center of the tubing sat at the edge of the outer fender.

Here's some beginning pics, watch for updates as I go.

http://gitout.com/v-web/gallery/d/15225-1/bumper03.jpg

http://gitout.com/v-web/gallery/d/15214-1/bumper10.jpg

http://gitout.com/v-web/gallery/d/15221-1/bumper01.jpg

http://gitout.com/v-web/gallery/d/15227-1/bumper04.jpg

http://gitout.com/v-web/gallery/d/15237-1/bumper09.jpg

I will keep all my pictures as I go posted, but you can see everything I take at this link
http://gitout.com/v-web/gallery/v/Readers-Rides/JR/bumper/

[CSaddict]

Good stuff Fookle.

[old_man]

lookin good. Don't know if it is in your plans, but you might want to extend those brackets back and pick up a couple of more mounting holes for strength. If you do it right, you can integrate the brackets into a steering brace as well.

Keep up the good work.

[WheelinJR]

lookin good. Don't know if it is in your plans, but you might want to extend those brackets back and pick up a couple of more mounting holes for strength. If you do it right, you can integrate the brackets into a steering brace as well.

Keep up the good work.

yeah thats part of my "yeah I know" list up above. I plan on making the longer brackets a seperate piece when I do make them, that way when I get tired of this bumper and I build another, I can re-use the brackets.

[rehab]

looks alot like the one we made, it looks good!
heres the ours:
http://i21.photobucket.com/albums/b298/88jeepcherokee/mounds%2012-20-06/IMG_0030.jpg

[barillms]

Looks cool, nice and simple. You might have just change my mind on my plans I had! thanks!

[chopperdog]

All your fab looks great, by the way what year is your rig and what are you going to do with the (goofy looking prerunner bar) that you had. I am interested in one If you want to get rid of it.
Thanks

[WheelinJR]

All your fab looks great, by the way what year is your rig and what are you going to do with the (goofy looking prerunner bar) that you had. I am interested in one If you want to get rid of it.
Thanks

Its a 91 Laredo

Im thinking of donating it to a NAXJA giveaway like NWFEST or something of some sort with the entire bumper and tow hook brackets all attached.

[chopperdog]

Mine is a 98, little different bumper style. Thats cool about the giveaway though

Thanks

[WheelinJR]

Mine is a 98, little different bumper style. Thats cool about the giveaway though

Thanks

well the prerunner bar isnt application specific, whoever put it on just drilled two holes int he bumper and bolted it up

[Stumpalump]

Do you see the part of the body or radiator support that comes in from the mounts then drops down an inch or so? The very front bottom of the body between the mounts. I trimed mine off at the point it starts to drop down and bolted a small size angle iron from side to side to clean up the front. It gained a bit of clearance and added strenght in case you run up under your bumper. Oh nice job!!

[WheelinJR]

Do you see the part of the body or radiator support that comes in from the mounts then drops down an inch or so? The very front bottom of the body between the mounts. I trimed mine off at the point it starts to drop down and bolted a small size angle iron from side to side to clean up the front. It gained a bit of clearance and added strenght in case you run up under your bumper. Oh nice job!!

my skid will cover that, cutting it won't gain me any clearance...

[redbeard]

Here are a few shots of the one I built about 4 years ago. It's still holding up quite well.

http://www.jeepforum.com/gallery/files//1/0/3/0/4/brianflex.jpg

http://www.jeepforum.com/gallery/files//1/0/3/0/4/P9160037.JPG

http://www.jeepforum.com/gallery/files//1/0/3/0/4/P9160036.JPG

[FiFo]

I’m going to have to copy from you guys liberally for my front bumper. Those are some nice bumpers you guys got.

Rehab, have you had any cooling problems with the winch that high up? My concern with mounting my winch up there is limiting airflow to the radiator.

[WheelinJR]

I’m going to have to copy from you guys liberally for my front bumper. Those are some nice bumpers you guys got.

Rehab, have you had any cooling problems with the winch that high up? My concern with mounting my winch up there is limiting airflow to the radiator.

run your backup fan constant, should make up for it...

[rehab]

I’m going to have to copy from you guys liberally for my front bumper. Those are some nice bumpers you guys got.

Rehab, have you had any cooling problems with the winch that high up? My concern with mounting my winch up there is limiting airflow to the radiator.

there is a slight problem with it. when driving on the express way at 70 mph its fine, but as soon you accelerate 5 mph the temp skyrockets due to the wind resistance change and no air goes into the radiator. on the trial it stays right at 210. im in the process of designing a new one with the winch mounted a lot lower with a greater approach angle.

[WheelinJR]

updates!!!

I finished the bumper today, did a little grinding, hit some spots with the DA, and sent it off to powdercoat.

Will post installed and finished pics on Tuesday when it comes back from powder coat. I opted for our smooth satin black finish. It should look real good.

Here are a few I took right before it was sent out. Beauty part is the end cost, working where I work has its perks...

1. steel ($21 in 1.75" tube, $3 in 1" tube, and $5 in 12 guage for the top)
2. time (free)
3. welding (free)
4. powdercoating probably $10-$15

I have about 2 hours labor into it. 2 hours and about $45...well worth it.

http://gitout.com/v-web/gallery/d/15338-1/bump01.jpg

http://gitout.com/v-web/gallery/d/15340-1/bump02.jpg

http://gitout.com/v-web/gallery/d/15342-1/bump03.jpg

[XJ_ranger]

http://gitout.com/v-web/gallery/d/15340-1/bump02.jpg



roof rack on the floor there?

who runs that sheetmetal shop?

[WheelinJR]

roof rack on the floor there?

who runs that sheetmetal shop?

I work for Warrior Products, as the IT/E-Commerce guy/CNC programmer/Lead Trainer/Production worker. Way too many slashes huh?

http://www.warriorproducts.com

[aparke4]

are you guys going to make tube doors for the cherokee?

[WheelinJR]

are you guys going to make tube doors for the cherokee?

They might decide to do them some day, but I wouldn't expect it to happen anytime soon. We're too busy.

[WheelinJR]

not to sound too excited, but my bumper is back and I am putting it on at my lunchbreak. woo!

I'll post some pics tonight when i get home from work of the finished and installed bumper (minus skid plate and lights, still gotta do that part)

[WheelinJR]

All done, pics here.

http://www.naxja.org/forum/showthread.php?p=243399262

[LABMBA87]

JASONRJR-
You never replied about those shackles. Any word?

[WheelinJR]

JASONRJR-
You never replied about those shackles. Any word?

I will reply.

[TORX]

Do you have a final weight on it? Looks light but stout, nice.

TORX

[WheelinJR]

Do you have a final weight on it? Looks light but stout, nice.

TORX

I didn't weigh it, but when I pulled my stock bumper/towhooks/prerunner bar that I had before it felt about the same, pretty light. Id wager 40-45lbs maybe...

[guillermo]

WheelingJR... You would'nt happen to have a picture of your XJ with the goofy pre-runner light bar on it would ya ? I want one for my stock bumper and am looking for ideas. Thanks.

[WheelinJR]

Here's a link to my photo album. I have a stupid amount of pictures on there, and I am sure you will see it.

http://gitout.com/v-web/gallery/v/Readers-Rides/JR/

[guillermo]

Thanks...thats just what I was looking for. Nice work on that new bumper.