Benmack1's bumper project

[benmack1]

First, I am not a fabricator so keep that in mind when viewing. I am new to this wheelin stuff and having a ball tinkering around with a cheap TJ I picked up last year after it was wrecked in the front. I did some repairs and now want to get out with the guys on the trails. The first thing I decided I needed were some bumpers (gotta drag my tail off the rocks).

I really wanted to be able to say built not bought when all is said and done and hell, what else do I have to do anyway so I bought a welder. Once I got said welder, I didn't know what I was doing so I took a class at the local community college last winter and it was a great confidence builder and I learned alot of beginner technique's to get me started. Anyway, here are my bumpers. Caution, this is pic heavy.

Front bumper (winch planned in time. I have a used 8274 sitting in the shop and will get that on at some point but I am trying to do things right as I go and I am SLOOOOWWWW!).

I made it too heavy was my first mistake but it will be the most solid part of the jeep I guess. this is 2x4 1/4 in rectangular tubing. 3/4x2 flat stock for the clevis mounts and I built the mounts to surround the entire frame as a chanel and welded it up from angle iron. Bolted 2 on top, 1 on the bottom, grade 8 hardware into the factory holes.

Drivers side, mount was truncated in prep for a steering box skid.

underside mount.

Steering box skid - this took me forever to get my angles the way I wanted them. Built from scratch, just formed it up with cardboard and then went at it.

Finished product, ends welded in and some paint.

More pics in the next post

 

[benmack1]

Looking down into the steering box skid from drivers side front corner.

from behind, looking at the pitman arm for clearance

 

[benmack1]

Now for the back end. Same material, but wanted a swing out for the tire. I bought a spindle from a to z fabrication. Supposed to be stronger than a regular trailer spindle. Hopefully it is!

Drilled through the bumper blank. I thought I was going to die doing this. Used cutting oil and a hole saw but I have some learning to do before another one of these. It worked out but good grief, took forever.

Welded in the spindle.

Use some 3x3 square tubing to set it out from the frame and made some flat stock (1/2 in plate) mounting plates.

View attachment 75162

 

[benmack1]

Made some frame tie ins and gusseted them. Used 3/8 plate I had for that. Overkill I think but it's what I had.

 

[benmack1]

Swingout frame from 2x2 1/4 in tubing. I welded too fast, got some warpage on the bottom. Damn it all!!!! Won't hurt anything, it's straight otherwise but I learned a lesson to jig things and weld around and let things cool.

Perch for the swingout to clamp into.

Added a holding pin and stop. Was following a guy over on jeep forum. He was a great help.

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Welded on a De Stache clamp. Was very happy with this. It holds it in and down in this configuration.

 

[benmack1]

Added a 2 inch LED for a 3rd brake light to be legal. I used a piece of 2 1/4 tail pipe, cut it short and tacked to the tire mount. The LED grommet fit perfectly and it sits in the center of the spare. Connected into the factory line coming for the 3rd brake light and done.

That's it. Not perfect, too heavy but I had a great time doing it.

 

[jeepinmatt]

Looks great man! I rebuilt a rear bumper for a guy and did the clamp and latch exactly like that. Worked out very well.

 

[OnlyOneDR]

Very nice, I like it. Getting ready to build a tire carrier for mine soon, still working on the rear bumper...