[Moogie]

After getting some minor damage to the front of the Jeep on my last outing, i decided it was time to make a recovery bumper.



But first i needed to trim the lower sections of the front wings to allow the bumper to wrap around the sides.
As there is a write up on Go jeep on how to carry out this mod, here is just a couple of picks of the process.













With that completed i am now in the process of designing the bumper.
I want to keep the bumper as neat as possible but it has to be able to accommodate a winch at a later date. Thinking of something along the lines of the one on Eric's XJ.





I plan to make the centre section of the bumper (where the winch will be) out of 6mm (1/4) plate and the side sections out of 4mm(5/32). Also need to make new brackets to mount the bumper to the chassis out of 6mm.

[Moogie]

Made a start on the bumper.
Headed off early to my mates work to get some steel guillotined and folded.







The centre section of the bumper is made out of 6mm(1/4).





The end sections are made of 4mm(5/32) and folded in a similar way but with a taper.



And then the corner sections. The gap at the corner will be filled in with a piece of rounded steel.



When i got back to the garage with all the bits of steel i needed (dam, it was heavy ), i offered up the centre section and prepared to make brackets to mount it to the chassis.



The brackets are made out of 10mm(13/32). A little heavy but i had it lying around and decided to use it up. I kept them quite long to spread any forces evenly along the chassis rails.



The over hang is kept to a minimum to help the approach angle.



Thats as far as as i have got for now, more later.

[Moogie]

Made a little bit more progress.

Got the end sections attached and filled in the hole in the corner.





With the new bumper you get a much better view of the front tyres. Also there is less of a change of catching it now.



The sides of the bumper are trimmed so that it is a continuation of the wheel arch to aid wheel clearance.



Even got the spot lamps refitted.


Another night of fabrication and it should be ready to be fully seam welded. Suppose i'll have to put a lick of paint on it then.

One thing i have learned while making this bumper, is that when tack welding without a mask, you get a nice sun tan, OUCH!!

[jsee238]

nasty man. wish i had a equip like that to break metal. I just started on my rear bumper cut it all out of plate(already had it layin around) with a 4" angle grinder. welded it all up with stick E6011 it about done ill post pics when complete. keep up the sweet metal fab!!!

[Moogie]

Eventually got round to finishing the bumper.

I got the recovery eyes punched and welded into place. Also seam welded the entire bumper.



Filled all the dents with filler and sanded down, then gave it two coats of Zink primer.



Once dry, it was sanded with 600 wet & dry, then another two coats of gray primer.



Managed to get a coat of satin black on the back before it got too late at night.



The next day i got the primer all sanded and ready for the black.



Three coats of satin black later and all i have to do is let it dry.



Got it mounted to the Jeep and i'm very pleased with how it looks.
It had pulled a little with the welding but wasn't too bad.



I like the way you see lots more of the tyre now.



I was able to keep it quite neat to the radiator but big enough to accept a winch at a later date.



Even the corners turned out well. Amazing what body filler can do.



Now, let me see, what next? A rear recovery bumper?

[94HOCHEROKEE]

Pro comp mud terrains= no bueno

[Apostle]

Looks good, make me one now

[99Greenmachine]

Wow, looks nice...wish I had a shop like that to work with haha

[Moogie]

Originally Posted by 94HOCHEROKEE

Pro comp mud terrains= no bueno

For rock your probably correct, but we only have green fields and mud bogs over here and for that terrain they are excellent. (called Mastercraft Courser MT here)

[justanotherjpr]

Great fab work, really nice job. Did you pick up the three steering box bolts on the outside of the chassis rail?

[Moogie]

Originally Posted by justanotherjpr

Great fab work, really nice job. Did you pick up the three steering box bolts on the outside of the chassis rail?

Yes, the bracket actually goes about 3" further along the chassis rail and has another two fixing points.

[justanotherjpr]

Great, should be a great recovery point and keep you from pulling your frame apart with the steering box!

[sprintagogo]

Nice work Moogie. I made mine in my garage with a junior hacksaw and a nail file





It sounds as though you used all the mounting holes I did except for the 2 under the chassis rail that secure the anti-roll bar.