This isn't a write up or a how too but I'll give a pretty good description and a few pics. I literally just got done with the install. The bumper came securely packaged in wood and heavy cardboard. Some bracing was added to the rocker guards to keep them in shape. The bumper itself has beautiful welds and came primed and ready to paint. I gave it a light sanding and used Duplicolor's rattle can bed liner. I'll report later on it's longevity. The bumper ties in where the old bumper mounted and with two additional mounts using the frame rail where the gas tank skid or stock hitch would mount.
It also mounts at the rockers themselves. Mark @ Detours suggested cutting and folding the rockers but I went a different route. After the bumper was bolted in at the rear, I cut open a 3" x 4" "door" on the inner skins of the rockers. This was to bolt the bumper to the outter rocker sheet metal using the supplied thick "washer" plates and allen cap screws. After bolting them up using a little thread locker, I pop riveted two pieces of 1/8" aluminum over the cutouts and siliconed everything really well.
Removing the outter rocker cladding added sort of a gap where the stock flares end and the bumper begins. To eliminate this gap I cut the old plastic claddings to about flare size and shaped them with a grinding wheel. I then drilled new holes to mount them near the top (the old mount at the bottom was still used). I used stainless steel pan heads with screw covers on the outside to keep things pretty and nylock nuts on the inside panel. I think they tie the bumper into the stock flares pretty well.
Overall I like this bumper for it's mounting strength and to me, it looks pretty cool. Best thing is I finally got the 31 incher outta my interior... I love the smell of tire in the morning....not really, well I didn't mind but the woman made a few comments. I also like having the room back. I like the angle of the carrier following the lines of the hatch too. So here's a few pics any questions ask away.
Did you just drill new holes to move the plate right? I'm trying to remember the tailgate on my 91, and if it's possible. I really want this bumper though.
I used the right most holes on the hatch with the left holes on the plate and yes, I drilled two more holes in the hatch for the right holes on the plate. I had some 3m double face tape and put that underside the plate to keep it off the surface a bit and rattle free. In open holes on the left side of the old holder I reinstalled the screws and used screw covers to neaten it up.
looks good since you added that plastic to the fender flare. i never liked the way that bumper looked without it.. looked unfinished
I thought so too. Best thing is that it was virtually free to make the little flare add on from the old cladding. Besides the work all I needed to buy was a couple of stainless pan heads, washers, nylon lock nuts and screw cap covers. All gotten at Loews for around 12 bucks.