[HeepToJeep]

In the midsts of bringing my XJs suspension back up to par I designed some new heavy duty rear bumpstops. No photos at the moment, I'll work on it though.


Tools
Drill
Pencil
C-Clamp
Wire brush
Tape measure
2) 1/2" wrench
Welder (optional)
Sander, file, grinder or saw
5/16" drill bit made for steel
Right angle grinder and cutoff wheel

Materials
2) Hockey pucks
1) Spraypaint or undercoating
2) 1.5" X 1.5" X 5" Steel Tubestock
1) Epoxy suitable for rubber and steel
4) 5/16 nuts, lock washers and bolts (length based on where you mount yours)


1. Cut or sand 1/2" off one side of each hockey puck.

2. Using a cutoff wheel, cut a centered 1" X 3" slot into one side of each piece of tubestock, make your slots as clean and accurate as possible so your bumper is held securely. You'll wind up with 1" end-spacing and 1/4" side spacing if done correctly.

3. (Skip this step if you want to weld your bumpstops on) On the side opposite the slot, drill a 5/16 hole 1/2" from each end of the tubestock.

4. (Skip this step if intending to use a welder) Place the tubestock against the frame rail where you intend to mount them and mark then drill your bolt layout on each side.

5. Weld or bolt the tubestock onto the area of frame rail you have chosen and cleaned off.

6. Spraypaint or undercoat the tubestock and surrounding area with a couple coats, painting everything now assures a good rust barrier.

7. After the paint or undercoating has dried scrape a small bit of it off the 1" X 3" middle section inside the tubestock. (opposite the 1" X 3" slot you cut)

8. Apply epoxy to the flat spot you made on each hockey puck, then using a hammer or mallet drive one (flatside in) into each 1" X 3" slot of the tubestock until the epoxy makes good contact with the spot you scraped clean inside.

Once the epoxy has fully cured you're all done!

Wm

[ddeadserious]

Sounds like a good idea, any pics?

[captain_ruggy]

You should make this into a write up.

[hermantherugger]

Looking forward to seeing some pics

[Vinnie90]

Throw down some pics, and seems like a good idea.

[trailblaze]

yeah toss some pics...

my rear bump stops have rusted off?? one is missing soo i've not been flexing when i wheel, well not flexing big that is