Rear Bumper Build

John D · Feb 27, 2011

I decided it was time to change my rear bumper. I wanted something that more closely matched my front. I had been pretty happy with the old bumper, but it was really heavy and I never got around to adding the frame attachments. Also with a 35” spare it was dragging over obstacles. When I did my hybrid cage (adding more weight) it became apparent and the rear was really starting to sag. Add in three kids, tools, and everything else and the back really dropped.

Here she is without any gear…

I pulled off the old bumper and did the usual cut-and-fold.

I wanted to start with a good base so I ran some 2x3 3/16” tube into the frame rails, marked the holes, welded in some nuts and then put some ¼” plates around the tubes with holes to mount into the original bumper mounts.

I had a buddy bend up some 1.75” HREW and we started putting it together.

Put a nice plate over the top to clean it up.

Added the rest of decorative steel with holes and painted her up to match.

John D · Feb 27, 2011

Touched up the bottom of the quarter panels where the paint chipped and the brackets for the bumper end caps were.

And here it is all done.

At some point I will add something around the taillights to close that gap and finish it off, but I am pretty happy with how it turned out.

xcm · Feb 27, 2011

looks great, especially dig the sides... but is that 1/4" plate for the speed-holes? you do all those holes with hole saws? looks straight enough to be cnc'd though.

John D said:

John D · Feb 27, 2011

They are actually pieces of a bearing race for a wind generator. I have a friend who works at a plant where they stamp these out and sometimes they have tails laying around.

91to99 · Feb 27, 2011

Bumper looks great.
Just curious about how you replaced the nutstrip, I am wanting to do something similar. Do you have any pics of the mods you did to the unibody?

John D · Feb 27, 2011

Not sure what you are asking. I did not have any nut strips, but if you do you can just pull them out. The pic below shows the tube that slides INTO the XJ frame. I just marked the holes underneath, drilled holes and welded the nuts in.

91to99 · Feb 27, 2011

Sorry... I noticed that pic.. No nutstrip anymore i see that. The hole where the nutstrip goes is only like 3/4 in wide. I am assuming you just sawzalled it to the same size as your tube that fits in the frame.

John D · Feb 27, 2011

Okay, yeah sorry. I forgot I had cut that out.

RAM-ROD · Feb 27, 2011

Looks great just like the rest of your rig. See you in Attica.

John D · Feb 27, 2011

Thanks, you going to show me how to do one of those cool reverse wheelies at the dunes this summer? Only about 34 days to the opener...

RAM-ROD · Feb 27, 2011

You know it....We already have camp site reservations for Memorial day weekend and a week at the end of july.

VAhasnoWAVES · Feb 27, 2011

i have a question john... no rear tow point? or do i spy D-ring tabs under the bumper?

fyrfytr1717 · Feb 27, 2011

Looks nice! I didn't notice any mention of recovery points. Are the holes that are tucked away in these pics where the bumper meets the mounts intended for d-rings or something?

John D · Feb 27, 2011

Yes, those are D-ring holes.

chris420 · Feb 27, 2011

Love the old fourtrax.

XJRN · Feb 27, 2011

Dring tabs welded on?

John D · Feb 27, 2011

96XJ9705 · Feb 27, 2011

What happened to the H2 Recovery Vehicle sticker, I want one of those. Nice bumper BTW. I was going to do similar mounts but ended up bending a piece of 1/4" sheet and cutting a D-ring tab in it. Looks very good.

Curious if you are putting a tire carrier back then.

John D · Feb 27, 2011

I was going to build a carrier to go on there but I have had second thoughts. I only need the spare for the trail and the occasional long road trip so I think I will just throw it in the cargo area. A 35" tire and wheel plus enough steel to keep it from falling off is a ton of weight. I really don't want it hanging off the back anymore. The space is tight in the back because of the cage, but I think I can come up with a mount that will still allow tools and parts.

MoparManiac · Feb 27, 2011

Bumper just looks out of place to me.

Clean fab work though :thumbup:

Rear Bumper Build

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