$100.00 Rear Bumper

[Israel]

There are a lot of different threads on bumper builds on NAXJA providing almost as many variations of what can be done. To give back to the NAXJA community, here is my version of a rear bumper.


Part 1: Materials

(1) length of 2”x5” pipe 3/16” thick and 66” long
(2) lengths of 2”x5” pipe 3/16” thick and 19” long
(2) lengths of 2”x3” pipe ¼” thick and 6.5” long
(2) lengths of 2” flat bar ¼” thick and 17” long
(2) lengths of 4” flat bar ¼” thick and 13.5” long
Various lengths of flat bar to cover the ends of the pipe.

The total for all the steel came to $96.87. If I had been thinking, I would have just ordered my 2”x5” pipe 104” long, my 2”x3” pipe 13” long, my 2” bar 34” long and my 4” bar 27” long since as I found out later, they charge per cut and I have access to a horizontal band saw. The total cost would have been closer to 80.00. Oh, well.

Here is a pic of the main bumper piece. It is 66” long. The tapers at the ends were done by measuring 12” from the ends and 1.75” down from the top and drawing a line between the two. I made the cuts with a die grinder with a cut off blade on it. Both sides took about 15 minutes to cut. The hole through the center was done by tracing the outline of the receiver in the center of the bumper and then drilling a ½” hole at each corner of the tracing. I then connected the holes with the die grinder and cut off blade. The receiver will go through the bumper sticking about 2” out from the face of the bumper and be welded on both sides.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/Mainbumperpiece.jpg

These are the two side pieces. They have a 15* cut on the end that will be in the wheel well and a 2” recess cut on the other end to fit on top of the main bumper piece.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/Sidepieces.jpg

These are the brackets that will bolt to the stock 8 mount holes. I will be drilling an additional 4 holes per bracket on the corners just for some extra beef. I believe I drilled the holes with a ½” drill bit which will allow some adjustment when bolting the bumper on.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/Bumpermountbrackets.jpg

Here are the two bumper spacers. I want the bumper to almost be flush with the hatch so I cut the body of the spacers to be 2.5”. This will put the face of the bumper about ½” out from the hatch. As you can see, I cut off three sides of the remaining material to make 4” long tabs. I’m going to cut a pair of slots in the bumper which they will be inserted through and stick 2” out from the front of the bumper. Then I’ll weld two ¼” pieces to the sides of the tabs and drill a 15/16” hole through the three pieces to make a pair of D-ring shackle hangers. The thought is that any pull forces on the D-rings will be directed through the bumper to the mount plates and frame rail strips instead of to the bumper, then to the spacers and mount plates.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/Bumperspacers.jpg

Frame rail strips. They will be drilled for the 3 holes each as the bumper is being assembled. In all, the bumper will be held to the Jeep with 22 bolts.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/Framerailpieces.jpg

[Israel]

Part 2: Assembly

The stock holes that access the inside of the frame rail are oval and spaced up from the inside bottom of the frame rail. Using a reciprocating saw, I cut the material out from below the oval so that the frame rail strips can sit flush with the inside bottom of the frame rails.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/widenedhole.jpg

Here the brackets and frame rail strips are being bolted to the Jeep. The additional 4 holes per side can be drilled through the brackets and the body of the Jeep at this point, although I still haven‘t gotten around to it. The frame rail strips should be spaced out the same distance from the brackets as your spacers, 2.5” in my case. Yes, the hitch will be coming off before the bumper is done.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/Bracketassembly.jpg

The spacers go next and the assembly is welded.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/BracketsWelded.jpg
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/WeldingBumperSupports.jpg

Next, we welded the hitch in the center of the bumper as well as some 2” flat bar to the ends of the main bumper piece. Just for kicks, I used some of the extra steel from the tapers I put on the ends of the main bumper piece to brace the back of the receiver. Mmm.. Beefy!
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/BracingWelded.jpg
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/EndsCapped.jpg

Slots were then cut through the bumper by drilling the top and bottom of the slot and slicing a thin piece of metal out wide enough for the spacer tabs to slide through. The bumper was then placed onto the spacer tabs which are bolted to the Jeep. The ¼” plates were added to the sides of the tabs to make a ¾” thick tab for my D-ring shackles and the tabs were welded to the bumper.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/BumperFitted.jpg

The two side pieces were then fitted and spot welded in place and the whole assembly was unbolted to be finish welded on the bench. The rest of the pipe ends were also capped at this time.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/D-RingTabs.jpg
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/WeldingBracketstoBumper.jpg

Here is a picture of the complete bumper bolted temporarily back to the Jeep for the trip home where it would be painted.
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/WeldingComplete.jpg

[Israel]

Part 3: Completion

Here are a few miscellaneous pictures of the painting process and the finished bolted to the jeep.

http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/ReadyForPaint.jpg
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/BumperPrimered.jpg
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/BumperPainted.jpg
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/Completebumper.jpg
http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/Clearancewithnewbumper.jpg

[dizzymac]

GOOD JOB !! Glad you gave a lot of pics too. I need to replace my rear bumper, guess I'll be trying that...thanx.

[TRAILREADYXJ]

Good work and pics! I definitly need to make some bumpers! You may have just bumped them up on my to do list :).

Looks like you could use more tire to go with those TJ flares though :).

[aparke4]

very cool... i guess with that design you have to tuck the rear quarter panels...what was your method in doing so? i am ok with a welder but i have seen some people tuck and tack with pop rivets... i am doing this soon so i want to do it right. thanks. oh yeah thats awesome work by the way...bumpers like that that come with integrated hitch from tomken or another brand run up to 300 to 350... cool work

[Israel]

Good work and pics! I definitly need to make some bumpers! You may have just bumped them up on my to do list :).

Looks like you could use more tire to go with those TJ flares though :).

Yeah, 35s are in process right now.

[Israel]

very cool... i guess with that design you have to tuck the rear quarter panels...what was your method in doing so? i am ok with a welder but i have seen some people tuck and tack with pop rivets... i am doing this soon so i want to do it right. thanks. oh yeah thats awesome work by the way...bumpers like that that come with integrated hitch from tomken or another brand run up to 300 to 350... cool work

The quarter panels turned out kind of hacked so I wouldn't suggest copying what I did. If I could do it again, I'd fold where everyone else does instead of higher. I think it would have come out cleaner.

[RCP Phx]

Access to the bolts must be fun.Mine is so tight to the body that I sleeved mine so I can get straight at them with a rachet.
http://www.hometown.aol.com/rpayne9421/images/rear%20bump1.jpg

[Israel]

Access to the bolts must be fun.Mine is so tight to the body that I sleeved mine so I can get straight at them with a rachet.


It actually isn't too bad once you get the bolt started. I didn't plan for it, but there is just enough room for me to get my 3/8ths ratchet with a short socket in there. If I had mounted it any closer, I would have had to cut the sheet metal below the brackets to get to the bolts. At any rate, it isn't meant to be taken on an off regularly anyway, right?

[STEELFISH]

Nice job, however I have some food for thought. you stated that it was attached to the jeep with 22 bolts, however when you use your hitch to pull you are pulling off of 1 pin that is a total of 1/2" thick. Oh and when you load your jeep on a trailer behind your tow rig you haul 6000# off of that same 1/2 pin....I think We (including me) over bolt a lot of parts...I guess more is better than less..

Once again nice job, I like how it looks.
J:cool:

[Israel]

Nice job, however I have some food for thought. you stated that it was attached to the jeep with 22 bolts, however when you use your hitch to pull you are pulling off of 1 pin that is a total of 1/2" thick. Oh and when you load your jeep on a trailer behind your tow rig you haul 6000# off of that same 1/2 pin....I think We (including me) over bolt a lot of parts...I guess more is better than less..

Once again nice job, I like how it looks.
J:cool:


Good point. But as you say, more is better than less. I'd hate to be the guy who's bumper was ripped off while strapping some one out! :wow: :doh:

[Ramsey]

That turned out real nice.

[ILLXJ]

Nice job, however I have some food for thought. you stated that it was attached to the jeep with 22 bolts.J:cool:
Dang, mines only got 18.:banghead: Looks real good.:clap::yelclap: JIM.

[Israel]

Thanks for the compliments everyone! :D

[87manche]

Nice job, however I have some food for thought. you stated that it was attached to the jeep with 22 bolts, however when you use your hitch to pull you are pulling off of 1 pin that is a total of 1/2" thick. Oh and when you load your jeep on a trailer behind your tow rig you haul 6000# off of that same 1/2 pin....I think We (including me) over bolt a lot of parts...I guess more is better than less..

Once again nice job, I like how it looks.
J:cool:
i think the difference there is that the 1/2" pin goes through a suitably large piece of metal, and the bumper is bolting into sheetmetal. If you didn't spread the load out you'd just pull the bolts out of the sheetmetal and make a jolly mess.

[OT]

i think the difference there is that the 1/2" pin goes through a suitably large piece of metal, and the bumper is bolting into sheetmetal. If you didn't spread the load out you'd just pull the bolts out of the sheetmetal and make a jolly mess.
I like your bumper MUCH better.
Who says parts have to look good, am I right?

[87manche]

I like your bumper MUCH better.
Who says parts have to look good, am I right?
well, you're the man who would know :)
I thought having crappy looking parts on your rig was an MWC requirement.

[MogifiedXJ]

Man, that's a sweet lookin bumper...you've done a really good job with it.

[dfreeman616]

another important thing to remeber about all the bolts is that this bumper is designed for recovery as well, as mentioned, which can be more force than a trailer rolling on (ideally) properly inflated tires.

[TrailHunter]

I hate to be a stickler, but I'm looking at the pics where you're painting them. I dont' see the eight additional holes that were to be added to the widened builkhead mounts and the inner frame rail strip doesn't seem to have any holes in it either. Is it just an illusion in those pics?

Those are some nice arc beads you've laid down btw.

[Israel]

I hate to be a stickler, but I'm looking at the pics where you're painting them. I dont' see the eight additional holes that were to be added to the widened builkhead mounts and the inner frame rail strip doesn't seem to have any holes in it either. Is it just an illusion in those pics?

Those are some nice arc beads you've laid down btw.

Good eye. The frame rail strips didn't get drilled until after the bumper was painted since my welding buddy ran out of time and had to go to his "real" job. So the holes were drilled and nuts welded to the stips the next morning.

As for the 8 extra holes, I still haven't gotten to them. They'll hopefully be done by Fall Fling.

Thanks for the compliment on the welds, but I didn't actually do the welding. My welding skills are fair, but the guy who did them for me was a boiler welder for 40 years and offered to weld it up for free. I would've been a fool to pass that offer up.

[Ludakris]

Access to the bolts must be fun.Mine is so tight to the body that I sleeved mine so I can get straight at them with a rachet.
http://www.hometown.aol.com/rpayne9421/images/rear%20bump1.jpg


thats what I have been planning on doing.. guess once again my new idea, isnt so new.

[themangeraaad]

So how much for one of those bumpers? :D I need bumpers... bad... Got the lift... Got the tires... Still stock bumpers... its sad. Haha. Awesome bumper, looks great. Great work on it.

[pro-rallye]

wow, that looks almost exactly like mine does except i don't have clevis attachments and my side protectors are flared out to match my tj flares. nice work! i dig the low pro look

[Stone Dragon]

Outstanding work! Looks like a fun project!

[WobblesXJ]

Wow and I couldn't even get enough 2x5x3/16 tubing for under $100. They wanted $18/ft here.

[Israel]

Wow and I couldn't even get enough 2x5x3/16 tubing for under $100. They wanted $18/ft here.

Please tell me you're joking! The place I got it from was selling it for $7.50 per foot. Sounds like you'd be better off buying one from C-Rok or something similar.

[XJ_Vikings]

I found a machine shop down the road oddly enough that basically gives away their scrap. I think in the end it was like 5.50-6.00 /foot. Search around a little more and see if you can find any machine shops that just want to get rid of their scrap.

[WobblesXJ]

yeah no doubt, needless to say I didn't buy from that place.

[Mr.OverKill]

the method of attachment is baisicly the same and i am tieing in the bumper too the tow hitch as well to create a sandwich out of the "frame" rails ( the hitch mount goes to the bump stops ) and i used two pieces of 3/4 in plate for the clevis mounts, i will give more details as i finish it up but for now here are the only pics i have of the bumper
http://i6.photobucket.com/albums/y241/steagall9301/08_09_06_1940.jpg
boy i need a better camera
http://i6.photobucket.com/albums/y241/steagall9301/08_09_06_1941.jpg
still need to trim the rear quarters and finish all the welding but it was truly well under $100 by about $95.50 ( $4.50 for electricity at home ) i will finish welding it out at my work in the next few days

[TheWarWagon]

Thanks for the compliments everyone! :D

I have to commend you on your insanely talented fab skills, but most of all; having GIR as your avatar. That's awesome.

[IntrepidXJ]

nice job.

i just skipped using the weak factory bolt locations on my rear bumper altogether

http://pictures.myxj.net/rearbumper3-15-06/DSC08581.JPG

http://pictures.myxj.net/prep4moab4-9-06/DSC09121.JPG

:D

[Lawn Cher']

Nice job, however I have some food for thought. you stated that it was attached to the jeep with 22 bolts, however when you use your hitch to pull you are pulling off of 1 pin that is a total of 1/2" thick. Oh and when you load your jeep on a trailer behind your tow rig you haul 6000# off of that same 1/2 pin....I think We (including me) over bolt a lot of parts...I guess more is better than less..

Once again nice job, I like how it looks.
J:cool:

I don't know about the rest of you, but I use 5/8" hitch pins.

[Israel]

I have to commend you on your insanely talented fab skills, but most of all; having GIR as your avatar. That's awesome.

LOL! Thanks! He's the scandalous bloody Gir, no less!

i just skipped using the weak factory bolt locations on my rear bumper altogether

So you just used the holes in the frame rail? Since a tow hitch only uses those holes, it should be strong enough, but it would still make me a little nervous. I like the stepped look of your bumper, by the way. I'm thinking of doing something similar in the front.

[IntrepidXJ]

So you just used the holes in the frame rail? Since a tow hitch only uses those holes, it should be strong enough, but it would still make me a little nervous. I like the stepped look of your bumper, by the way. I'm thinking of doing something similar in the front.

yes. I was originally planning on using some of the original bumper mount bolts, but I wanted my bumper as tight to the body as I could get it, and I wouldn't be able to get to those bolts if I had. I'm not worried about strength, since the received I used to recover from didn't mount in as many places and worked just fine.

The bumper was made from my old rock rails, so it was a pretty cheap build for me also ;)

:)

[GermanXJ]

I am gettin ready to build one for the XJ i am racin to Africa in the fall next year. I think your design is goin to Africa. Good job.

[Israel]

I am gettin ready to build one for the XJ i am racin to Africa in the fall next year. I think your design is goin to Africa. Good job.

Sweet! Fame and fortune here I come! I'd better start on my paparazzi insults.

Hope the race goes well for you. How many miles (or kilometers) is it total?

[DrMoab]

yes. I was originally planning on using some of the original bumper mount bolts, but I wanted my bumper as tight to the body as I could get it, and I wouldn't be able to get to those bolts if I had. I'm not worried about strength, since the received I used to recover from didn't mount in as many places and worked just fine.

The bumper was made from my old rock rails, so it was a pretty cheap build for me also ;)

:)
If you are planning on going in the frame rails like that you need to reinforce it though if you plan on running a swingout.

Mine is set up this way and the frame rails are starting to split on the bottom. It is just too much weight.

[jdogg4]

Access to the bolts must be fun.Mine is so tight to the body that I sleeved mine so I can get straight at them with a rachet.
http://www.hometown.aol.com/rpayne9421/images/rear%20bump1.jpg

Tight or not that looks about the best way to access them no need busting your knuckles getting in and on your back or what not to get to all 4 bolts. Easy on easy off. I guess cutting some holes in the bumper and using some sch40 pipe or something to sleave them might not be so badkeep stuff out of the bumper. WOW thats got the burners on full thinking about that now.

[IntrepidXJ]

If you are planning on going in the frame rails like that you need to reinforce it though if you plan on running a swingout.

Mine is set up this way and the frame rails are starting to split on the bottom. It is just too much weight.

well, you know where my tire carrier is.....that's not a concern for me :kissyou:

[GermanXJ]

Sweet! Fame and fortune here I come! I'd better start on my paparazzi insults.

Hope the race goes well for you. How many miles (or kilometers) is it total?

It is from A-dam to Dakar.About 3,600 miles.
Its one of those races with a $500 limit on the purchace price of the car or truck. When you get to Africa the truck is given away for charity.
Should be fun.

[Tim_MN]

A local steel supplier has a yellow page add that says "open to the public" and they sell scraps, damaged stuff and miscuts for .25 cents a pound. I have found +10ft lengths of 2x2, 2x4 and 2x6 .120, .180 and .250 thick rectangular tube in the scrap racks. My whole front bumper project cost me about $35.00 for the steel.

[SCW]

A local steel supplier has a yellow page add that says "open to the public" and they sell scraps, damaged stuff and miscuts for .25 cents a pound. I have found +10ft lengths of 2x2, 2x4 and 2x6 .120, .180 and .250 thick rectangular tube in the scrap racks. My whole front bumper project cost me about $35.00 for the steel.

Yeah, mine was about $40 till I added in the hitch mount, that was $32 all by itself!!!

[Gravesdiggerxj]

tech to the top: because israel's bumper is cool...
and so I don't have to keep searching :)

[WheelinJR]

It's pretty cool the stuff these guys do with some square stock and a grinder...

I'm still partial to my $40 (with powder coat included) tube bumper. Call me crazy :)

http://a776.ac-images.myspacecdn.com/images01/10/l_df68765b93d1f053b2fa1618f18bb3e7.jpg

[xjkevin]

heres my newly built rear bumper. cost about 150.00
http://i44.photobucket.com/albums/f18/jeepnzj/102_1466.jpg

[xjkevin]

http://i44.photobucket.com/albums/f18/jeepnzj/102_1467.jpg

[Israel]

tech to the top: because israel's bumper is cool...
and so I don't have to keep searching :)

I don't know if you caught my "parting my 96" thread, but the bumper is for sale. :D I got no shame!

[xjkevin]

no shame would be asking 200.00 for it...:roflmao:


I don't know if you caught my "parting my 96" thread, but the bumper is for sale. :D I got no shame!

[90Blue_XJ]

I don't know if you caught my "parting my 96" thread, but the bumper is for sale. :D I got no shame!

Wish I had known sooner. Mine is a copy of yours.