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Unread 03-30-2009, 05:05 PM   #1
AgitatedPancake
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WJ Rear bumper build *UPDATED 4/11/09*

Alright so I'm tinkering with a little mockup for the rear bumper right now, tell me what you guys think! Any input welcome.

I know its hard to see whats going on because of the colors of the cardboard, but yeah.

So I have it sticking out to protect the fender,





In the second picture, the part that says BES will be on the same plane as the white/blue that goes down to the bottom of the frame rail.

Here you can see the plane differences. I'm not sure how much I like that look, but I just threw it together a couple mins ago. This is where I need input!


I haven't welded the remnants of that peice to the floorboard so its pushing out, but here you can see how they will be for the final assembly.




For frame attatchments I'm looking at getting some 4x4 angle iron or 4x4 box tube (and cutting it out), so the side of the frame rails have material to weld supports to for the sides.



Example: Go from the angle iron/box out to the sides right on the bottom of the floorboards with 1" square tubing or something.



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Last edited by AgitatedPancake; 04-11-2009 at 07:03 PM..
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Unread 03-30-2009, 05:14 PM   #2
CaribouLouWJ
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mmmmm, Pizza


I like it so far...
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Unread 03-30-2009, 05:14 PM   #3
AgitatedPancake
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$5 pizza's and propel water =D
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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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Unread 03-30-2009, 05:17 PM   #4
CaribouLouWJ
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Stop, I'm hungry, lol
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2000 F350 PSD CC LB
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2002 WJ Limited
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Unread 03-30-2009, 05:25 PM   #5
CMARJEEP
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Looks nice but I don't think cardboard is going to hold up very well.
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Unread 03-30-2009, 05:45 PM   #6
lakailimited06
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AP, im sure you've seen this guys bumpers on MC but i figured id show you maybe it'll give you some more ideas i think they looks good..

http://home.comcast.net/~weghorst/WJ/wjBumpers/
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Unread 03-30-2009, 06:01 PM   #7
AgitatedPancake
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That bumper does look well designed, but I chopped alot of stuff out under the rear taillights AND have the gas tank raised which really change the lines of the bumper so I can't apply alot of the stuff from that bumper =/. My bumper is going to be probably half as tall as his, isn't going to bee hanging down much AT ALL (about 4" below bottom of tailgate)
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Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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Unread 03-30-2009, 06:21 PM   #8
lakailimited06
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true sounds like your all about performance and clearance, keep us updated i want to see pics
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Unread 03-31-2009, 03:10 PM   #9
AgitatedPancake
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Alright took another look today, and decided things would be much simpler if I chopped up to the floorboards instead of trying to cut all those angles. I'm much happier with the cutting, and its making my mounting solutions easier on me.

New cut:




I put the gas tank skid up to check clearance back there. Its also nice because the bottom of the frame rails are in the same plane as that sheetmetal still hanging off the back, I am literally gunan end up with my mounts going straight back off the framerails into the bottom plate of the bumper.


And now I'm thinking about cutting all of that sheetmetal out that I can, I can gain alot of space in here for storage if I bring the inside of the bumper as close to the gas tank as I can. Yeah, I still want to do a storage bumper, we will see if I can pull it off clean or not.
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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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Unread 03-31-2009, 03:34 PM   #10
skain8
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Looks good. I'm always a fan of homebrew builds.

The floorboard cuts should really cut down on the build. Keep us posted.
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Unread 04-01-2009, 04:10 AM   #11
sandman
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nice!!!! i like that its built for clearance.
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Unread 04-05-2009, 07:31 PM   #12
AgitatedPancake
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Alright got some plate and started the fab...here are some pics for ya guys.

1/4" plate on the bottom and outside of frame rails.


It will use all the bolts that the hitch and gas tank use. It may be a PITA to install as it and the gas tank have to go at the same time but oh well.




I got my bends started on the rear peice...


And the potential storage area.


It will end up with a little less than this


finish welding the frame rail "L"s.


I got pissed at my welder. I cleaned it all up with a wire wheel on the grinder, welded most of it up then the last 2-3 welds all got bad porosity...I cant figure out why. With the first one I thought it was because of wind so I shut my work area up, then the next one did it as well. I can hear and feel the gas coming out of the nozzle, and I cranked the output up to like 27cfh with no change. This has happened once before and went away on its own. I'm running a miller 180, 220v with .025 wire (I know a little thin for heavy metal like this.) and co2/argon mix.
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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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Unread 04-05-2009, 08:34 PM   #13
dmolaver15
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the bumper looks sick so far, i think i'll be looking back to this thread when it's time to build one for mine

PS Agitated: you have a PM
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Unread 04-05-2009, 08:53 PM   #14
AgitatedPancake
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Thanks man, PM replied!
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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
AgitatedPancake's Youtube Channel
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Unread 04-06-2009, 06:37 PM   #15
AgitatedPancake
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Got some more done today

I had to extend my L's, I didn't like how close the bumper was to the body.


Back side






around 4.5" to the bottom of the tailgate. I wanted it to stick out to where if I backed into something or got rammed my tailgate wouldn't take the hit.


In the storage area, I cut out a part that was intrusive and welded in a peice of plate. The area is about 42" wide, 7-8" deep and 4" tall...I can carry pretty much whatever I want back here (though I don't have the hitch in yet...)
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01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
AgitatedPancake's Youtube Channel
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