'91 XJ Rear Bumper Build - Doing it strong - JeepForum.com
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post #1 of 6 Old 07-29-2012, 12:33 AM Thread Starter
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1991 XJ Cherokee 
Join Date: Aug 2008
Location: Socal
Posts: 1,221
'91 XJ Rear Bumper Build - Doing it strong

I need a new rear bumper. It's either that or long-arms. I'm not really prepaired for that. So a bumper it is. I always overbuild everything,
knowing this I decided on 2x4 stock instead of 2x6. I got 10 feet of 3/16" at the local steel yard.
I also picked up some scrap 2" strap x 3/16" and a hitch receiver.

I was motivated by a couple of builds worth mentioning:
Paraleyes rear bumper build is the best I've seen. http://www.jeepforum.com/forum/f11/c...t-way-1007865/
Husslers Doing it Perfect is an exercise in free thinking. http://www.jeepforum.com/forum/f37/d...rrier-1331910/
Both contain a solid build and a classic design.

Hopefully, I can make one that looks respectable.

I made inserts

added ears

Gave it some shape

Centered and tacked it

and welded it up

I also trimmed the ends, added runners to protect the fenders, cut the cavity for the hitch, added the hitch and tail-light risers, finish welded.

Some time later

Cleaned up

I'm planning on adding chain hoops and strengthing the receiver. I'll add some random gussets,
weld in some low spots and final grind, then some bondo to smooth it out, prime and paint.

More pics to come

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post #2 of 6 Old 07-29-2012, 03:36 AM
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1996 XJ Cherokee 
Join Date: Feb 2010
Location: san diego
Posts: 110
Looking good! Great start! Im excited to see it all painted up! This is similar to what I would like to do when I get down to building mine!
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post #3 of 6 Old 07-29-2012, 08:29 AM
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2001 XJ Cherokee 
Join Date: Jun 2009
Location: Bucks County
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Nice job !

A nation that forgets it's defenders will itself be forgotten

01 Up Country 6.5 long arm
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post #4 of 6 Old 07-29-2012, 10:21 PM Thread Starter
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1991 XJ Cherokee 
Join Date: Aug 2008
Location: Socal
Posts: 1,221
Some progress

Added gussets to the hitch

Chain hoops



Removing the old hitch significantly improved the departure angle. I zip tied the trailer wiring for now, I'll fab a bracket for it.
I also plan on a swing out. I have a swing down hitch mount that is back on, it's functional but hides the bumper.

That's it for now
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post #5 of 6 Old 07-29-2012, 11:15 PM
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1992 XJ Cherokee 
Join Date: Oct 2007
Location: Rosamond, CA
Posts: 652
Don't mean to insult you, but your welds need to be better. Grinding and Bondo is no substitute for a good weld. Bad welds break, and I know you don't want that. Practice, practice, practice... find a guy who's really good and ask for advice. Search YouTube for welding videos, but be warned... half of those are flat-out wrong. Don't get frustrated; making really good welds is hard. Practice some more...

The road goes on forever, the party never ends....
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post #6 of 6 Old 07-30-2012, 12:09 AM Thread Starter
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1991 XJ Cherokee 
Join Date: Aug 2008
Location: Socal
Posts: 1,221
I never did get around to putting any bondo on it, just filled the low spots with weld and hit it with the grinder and flapper.

That hitch isn't going anywhere. Welds may not be pretty but the heat signature indicates good penetration. There is also some slop from the flux.
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