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Unread 01-20-2012, 12:38 AM   #1
DoctorTim
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Doing it right: Rear bumper swing out build.

Ok folks i've seen plenty of bumper builds, but not many amateurs like myself have made anything that looks nice at all. the main problem i have with most diy bumpers is they are weak, open up that big gap at the rear lower quarter panel, and they look like two-by-fours hammered onto the rear. In this thread i will be updating my progress daily. Note that i have very little experience with metal work (less than 5 hours of welding until today).

Your first step in any bumper build is to do a lot of research and planning. I went out onto the web to look for a good hinge design. I didn't like the spindle that sticks out the top and blocks the taillights. I really liked the idea of having the hinge on the face of the bumper, much like the one you see below.



the results of my search for a hinge is the following;

2.5" (length) piece of tubing that has an inner diameter of 1"
two Flanged sleeve bearings (product# 7815K49) from Mcmaster-carr (click to view the list and details)
3.5" long 3/4" dia bolt with corresponding nut and washers.

it will look something like this




so with the hinge out of the way, it was time to start researching what would be best for the main part of the bumper. i find that on many occasions people find 3/16" rectangle tubing (2"x4") has plenty of strength. However i found that 3/16" C channel is lighter and still strong enough for a bumper, and gussets can be added in any areas which need more strength. I started looking around my area for low cost metals. I found IMS, they have very low prices, discounts on anything you can find in the scrap metal section (30% off), and another discount for students (10%). I found a 7 foot piece of 3/16" C channel which measured 1.5" by 4", some angle pieces for the unibody brackets, and some 1/8" sheet metal for aesthetic stuff. got it all for 28 bucks.


First i made the unibody brackets. they are 2" by 2" angle, drilled holes and welded on the nuts for mounting. not completely finished with the brackets but they will do for now until i make the swing out. i kept the brackets a little long so i can decide how far out i want my bumper once it's ready to be welded on.


Next, i wanted to make something that would make my bumper blend in with the original shape of the jeep. This is what i ended up with. it's a little long right now but thats so i will be able to exactly match the rear bumper once it's mounted. I dont have pics of my making the folds, but its very simple. I cut a 20" by 10" piece of 1/8" sheet metal. Then I used a cut off wheel to cut halfway through the sheet along the lines that it would fold. this weakens the metal so it can be easily bent with a hammer. So i did that for both folds, and cut off the extra metal that was hanging below or hitting the fender flare.





i will update this as I progress with the build. I will also get better pictures when it's daytime. Feel free to comment and suggest!



im adding links on the bottom of every one of my updates to the next update so its easier to follow.

NEXT UPDATE

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Unread 01-20-2012, 05:40 AM   #2
whitexj98
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Mount the tire to the driver side so you can see when you back up!
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Unread 01-21-2012, 12:52 PM   #3
lilnapsak
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Dig ittt
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Unread 01-21-2012, 04:08 PM   #4
DoctorTim
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this will be reinforced later






i am about to start welding these on!!





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Unread 01-22-2012, 10:06 AM   #5
Desertwheeler
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Nice build so far, I am building a bumper/swingout right now as well. I like your idea of scoring the 1/8in plate for bending.
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Unread 01-22-2012, 11:13 AM   #6
DoctorTim
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unfortunately the side plating will be changed up a bit and it wont be one piece extending from the fender anymore. you'll see pics of it soon.

EDIT: came to this decision because the panels on the jeep are slightly curved, i would need a press to make the metal fit perfectly.
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Unread 01-22-2012, 02:22 PM   #7
DoctorTim
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I am getting really good penetration with my 110 flux core welder. Long arching does the trick.. I will clean up the welds later with a wire wheel.



a quick test fit



and once it's welded onto the brackets and bolted in i made the bends and corners with the help of jason (miteofthesun)







next step is to hide the gap under the taillights..



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Unread 01-22-2012, 02:54 PM   #8
eprovenzano
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This is a great idea... I will be building one in the not too distant future.
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Unread 01-22-2012, 08:26 PM   #9
Buzzstrike
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Caution.

Progress in your rear bumper swing-out tire carrier may induce people calling you and throwing money your way so that they may have one of your bumpers.

If I has said funds, "would you build me one?"

Your work looks good, and your research looks to be paying off.

Enjoy it.

Buzz.
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Unread 01-22-2012, 09:50 PM   #10
DoctorTim
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i would build bumpers to sell, but I have a job and school to kill my time beginning tomorrow. It takes me a whole weekend to build a basic bumper like this.





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Unread 01-22-2012, 10:17 PM   #11
DezertXj88
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Very nice, interested in selling these once your profect yours?
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Unread 01-22-2012, 10:42 PM   #12
Desertwheeler
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Quote:
Originally Posted by XJ-Tim View Post
unfortunately the side plating will be changed up a bit and it wont be one piece extending from the fender anymore. you'll see pics of it soon.

EDIT: came to this decision because the panels on the jeep are slightly curved, i would need a press to make the metal fit perfectly.
I see what you mean. I tried figuring this out today while working on mine. I too came up with a solution similar to yours.
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Unread 01-22-2012, 10:46 PM   #13
DoctorTim
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at some point I will make another. most likely not until i get time off work and/or school
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Unread 01-23-2012, 12:55 AM   #14
Snoopi8321
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Unread 01-23-2012, 07:58 PM   #15
DoctorTim
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ok se here's the basic bumper, had to paint it because the forecast said it was going to rain soon, and i wanted to drive around with it. it seems like it stiffened the frame a bit because i hear less creaking when i flex the suspension over speed bumps and zombies n stuff.. I will be buying materials for the swing out on thursday or saturday.






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