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Unread 04-12-2010, 04:08 PM   #1
DaveinHouston
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2003 TJ Wrangler 
 
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Another Swing-Out Spare Carrier Build

I know there are a lot of these out there but here's one more. A friend gave me a rear bumper (I think it's Rugged Ridge??) a few weeks back and I finally decided to install it. It didn't have safety chain hooks or d-ring brackets so I set the thing up in the garage and started to work on it. As I did I realized my existing spare tire carrier wasn't going to work with it so I decided to build one of those. Following are the photos with very little commentary. I don't know how to insert comments between photos so it'll be five per post.
Rather than drill a 1 1/4" hole (I don't have a bit that big) I used the Oxy-Acetylene torch to cut the hole top and bottom plus a slot from top to bottom to weld to. The hinge is from AtoZ Fabrication.

hpim1214.jpg   hpim1215.jpg   hpim1216.jpg   hpim1217.jpg   hpim1218.jpg  

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Unread 04-12-2010, 04:14 PM   #2
DaveinHouston
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You can see the d-ring brackets and safety chain catch in these photos. D-ring brackets are installed through the bumper and welded inside and out. I fabricated the carrier out of 2X2X1/8" square tubing. I bought 20' of it at a local steel supply for $44.00. The welds on the inside of the bumper on the d-ring bracket aren't that ugly, I was just too lazy to clean the slag off in there. I used 7018AC stick rods on all welds.
hpim1219.jpg   hpim1220.jpg   hpim1221.jpg   hpim1222.jpg   hpim1223.jpg  

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- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

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Unread 04-12-2010, 04:16 PM   #3
hightower2011
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lookin great! Man I need to learn how to weld... haha!
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Unread 04-12-2010, 04:20 PM   #4
DaveinHouston
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The tire support plate is part of a basket attachment that I've had laying around. I attached it so it is about 1/4" shorter than the tire is deep so it would pull the tire up tight against the frame and avoid having the dead weight of the tire hanging on the bracket. You can see the gusset welded to the bracket to help support it.
hpim1226.jpg   hpim1227.jpg   hpim1227a.jpg   hpim1227b.jpg   hpim1227c.jpg  

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- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

- NRA Life Member - Licensed to Carry and Do.
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Unread 04-12-2010, 04:27 PM   #5
DaveinHouston
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I didn't like the way I'd fabricated the lower part of the frame so I changed it...made it a little stronger. I spent a lot of time worrying with the latch for the carrier. I finally settled on using a 3/4" grade 8 bolt with sleeves imbedded and welded in the bumper and in the lower arm of the carrier. This is probably over-kill but I've heard so many horror stories of hinges breaking that I didn't want to take any chances. If the hinge breaks that bolt will hold, at least long enough to stop the Jeep. I also like that it takes some of the lateral load off the hinge while running down the road.
hpim1227d.jpg   hpim1228.jpg   hpim1229.jpg   hpim1231.jpg   hpim1232.jpg  

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- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

- NRA Life Member - Licensed to Carry and Do.

Last edited by DaveinHouston; 04-12-2010 at 04:56 PM..
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Unread 04-12-2010, 04:32 PM   #6
DaveinHouston
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These photos just show the latch, and some of my anal overkill. I couldn't help myself and fabricated an additional latch out of a mini-boomer from Tractor Supply. Plus there is a place for a pad-lock on the boomer. The handle on the end actually helps quite a bit. Another piece of junk lying around the garage. It took a few tries to get the 3/4" bolt adjusted just right.
hpim1234.jpg   hpim1234a.jpg   hpim1235.jpg   hpim1237.jpg   hpim1240.jpg  

__________________
- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

- NRA Life Member - Licensed to Carry and Do.

Last edited by DaveinHouston; 04-12-2010 at 04:50 PM..
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Unread 04-12-2010, 04:39 PM   #7
DaveinHouston
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I did quite a bit of "mocking up" with the carrier mounted on the Jeep. That spare gets heavy putting it on, taking it off......I debated a lot about whether or not to add a Hi-Lift bracket but finally decided to do so. The tire and Hi-lift are all mounted low enough so that I don't completely lose my rear view mirror view but it does obstruct the view. And yes the receiver hitch will still work but I have to use a drop hitch to clear the tire. After fabricating I painted the thing up in my "paint booth". I used Eastwood rust encapsulator, the Krylon primer and Krylon Automotive final coat. The white is courtesy of my wife. I would've gone black but what the heck. She thought it was "pretty".
hpim1240a.jpg   hpim1245.jpg   hpim1246.jpg   hpim1247.jpg   hpim1248.jpg  

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- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

- NRA Life Member - Licensed to Carry and Do.

Last edited by DaveinHouston; 04-12-2010 at 05:14 PM..
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Unread 04-12-2010, 04:41 PM   #8
MA88XJDude
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I actually really like the white. looks great!
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Unread 04-12-2010, 04:45 PM   #9
DaveinHouston
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So there it is all finished up. It is very sturdy with no movement at all. When you shake it you move the frame and the Jeep. Also no rattles or movement when driving. I am thinking about placing a small crossbar, hinge and latch at the top of the tailgate tied in to the carrier and in to the back of the Jeep. Again, this is probably overkill but it would absolutely eliminate any concerns about the weight of the tire pulling the carrier over. The entire fabrication probably took the better part of three or four days and cost around $100, not counting electricity for the welder and gas for the torch.
hpim1249.jpg   hpim1250.jpg   hpim1251.jpg   hpim1252.jpg   hpim1253.jpg  

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- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

- NRA Life Member - Licensed to Carry and Do.
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Unread 04-12-2010, 04:48 PM   #10
DaveinHouston
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Quote:
Originally Posted by hightower2011 View Post
lookin great! Man I need to learn how to weld... haha!
If you've got a Vo-Tech close to you they generally offer courses. It wouldn't take you long to learn. I couldn't get by with out it. Thanks.
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- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

- NRA Life Member - Licensed to Carry and Do.
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Unread 04-12-2010, 04:53 PM   #11
DaveinHouston
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Quote:
Originally Posted by MA88XJDude View Post
I actually really like the white. looks great!
Thanks. Yeah, it's not bad. It is a little different. It'll be all skinned up soon enough.
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- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

- NRA Life Member - Licensed to Carry and Do.
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Unread 04-12-2010, 05:05 PM   #12
TrynPas
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Looks Great!!! Thanks for the write up, this is my next project and I've got my own ideas of what I want, but seeing someone else do it makes it alot easier. VERY COOL!!!
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Unread 04-12-2010, 05:18 PM   #13
MA88XJDude
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Any chance of a side view shot of it now that its done? Just out of curiousity couldnt you have put the hi-lift jack down a little lower?
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Unread 04-12-2010, 05:46 PM   #14
DaveinHouston
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Quote:
Originally Posted by MA88XJDude View Post
Any chance of a side view shot of it now that its done? Just out of curiousity couldnt you have put the hi-lift jack down a little lower?
The way I built it I could only get it about 1/2" lower.....on the back side of the carrier. Had I planned a little better, or taken a little more time I would have mounted it on the front side of the carrier and dropped it down several inches. The last day of work on it I was getting tired and careless and I just wanted it done. I may take the time to move it down later. As you can see from the photos I could probably move it several inches down. That would also move some of the weight forward of the center of the carrier and help balance the weight of the tire.

Also I need to thank all the folks on JF that have posted their builds. I looked at tons of them before I decided how to build mine.
hpim1254.jpg   hpim1255.jpg   hpim1256.jpg   hpim1257.jpg  
__________________
- 2003 Rubicon - 4" Lift, 35" KM2s, 5.13 gears, winch
- 1968 CJ5 - Dauntless V6, T-86, Dana 18, D27 & D44

- NRA Life Member - Licensed to Carry and Do.
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Unread 04-12-2010, 05:53 PM   #15
MA88XJDude
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Thanks for the side view! I'll be looking at yours and other fellow jeep forum members build when I build mine down the road.
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Build thread:http://www.jeepforum.com/forum/f22/s...build-1066682/
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