Justin's Bumper Build Thread - JeepForum.com
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post #1 of 53 Old 06-10-2012, 01:51 PM Thread Starter
Justin_WJ
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Justin's Bumper Build Thread

well the time has come to build a front bumper....im leaning toward a bumper that looks similar to the iceland front winch bumper, but made out of steel. The bumper will be made of 1/4 inch and 7ga. mild steel and welded with dual shield flux cored wire.

Now for a little background info, Im a certified welder in bare wire mig, flux core mig, arc, Heli-arc, stainless and aluminum mig, and stainless and aluminum tig. Ive been a welder and fabricating in the industry for 8 years, so i have the knowledge and ability to do this, i just need some pushes in the right direction as far as design influence.

I will be keeping strict documentation of materials used and weld positions, as well as lots and lots of pictures. That way i can share the knowledge and design with the community. I will have a blueprint made of each part thats welded on with exact measurements.

OK, enought jibber jabber. Sorry fellas (and ladies), no pictures until about 2130hrs tonight, i work second shift (1600-0030) and my boss has graciously agreed to let me build the bumper during breaks and lunch. So i have about 2hrs a night to work on this thing. Best thing about it is I get to use scrap metal from the shop and will only be paying what the scrap company gives the shop per pound when the come pick it up (slim.....very slim). basically Ill be building this bumper for around $40 bucks minus the winch and shackles.

Enjoy!!!




2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #2 of 53 Old 06-10-2012, 02:52 PM Thread Starter
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image-78104510.jpg

Well, this is what we have to work with, first night of the build. Anyone with an Iceland bumper that could give me some measurements would be greatly appreciated

2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #3 of 53 Old 06-10-2012, 08:41 PM
platinum5.9
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I'm looking forward to this....

03 Grand/WJ-White 4.7HO/QD/242HD Clayton 6" LA,5100,Clayton skid,Custom Rockers,JK OME SS,17"Rock Monsters 33"Interco Irok ND,Muffler delete/MF cats,SOLID D30/BTF D44a,Fawkes,Projectors/HID
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post #4 of 53 Old 06-10-2012, 10:35 PM Thread Starter
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image-761946868.jpg

Got some measurements done tonight for the winch cradle, I'm going to make all of these parts out of 1/4" P&O mild steel.

2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #5 of 53 Old 06-10-2012, 10:48 PM Thread Starter
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Quote:
Originally Posted by platinum5.9
I'm looking forward to this....
Me too!

2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #6 of 53 Old 06-11-2012, 12:48 PM Thread Starter
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Small update...got the subframe cut so I can fit the piece of steel that bolts inside it. Both sides looks the same. These recovery points I made will be for sale soon as well. Along with the grade 8 hardware.

image-47732226.jpg

2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #7 of 53 Old 06-11-2012, 02:07 PM Thread Starter
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Got the grill cut away from the bumper as well.

image-926751905.jpg

2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #8 of 53 Old 06-13-2012, 01:11 PM Thread Starter
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Got all my supports bolted up today, I'm gonna clamp the top and bottom together tonight at work and weld them around the sides,
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image-929016574.jpg   image-2956215531.jpg   image-1841474200.jpg   image-2557828169.jpg   image-69301353.jpg  


2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #9 of 53 Old 06-13-2012, 01:40 PM Thread Starter
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image-2911071670.jpg

Just to give you an idea of how far the top piece stocks out

2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #10 of 53 Old 06-13-2012, 08:57 PM Thread Starter
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2x2 tubing welded on.

2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #11 of 53 Old 06-14-2012, 09:28 AM
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Just a question. Why didn't you use angle iron or box tube going into the frame for lateral and vertical support? Whats to stop the flat stock from bending up or down? I used 1/4 2x4 tube when I built mine.

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post #12 of 53 Old 06-14-2012, 09:33 AM
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Quote:
Originally Posted by gcjeeping View Post
Just a question. Why didn't you use angle iron or box tube going into the frame for lateral and vertical support? Whats to stop the flat stock from bending up or down? I used 1/4 2x4 tube when I built mine.
I agree. Most commercially available bumpers use an L shaped bracket in the frame rail there, and bolt through both the bottom and side for extra strength.


Excited to see this, as you're building mine next.

~Aaron


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post #13 of 53 Old 06-14-2012, 01:25 PM Thread Starter
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Yea I looked at ALOT of bumpers online last night and I'm going to weld some 2" wide 1/4 inch thick supports on the under the subframe brackets. Basically it will look like a box with 3 sides, as well as weld some inside the frame rail. Like i said, this is a learning experience for me as far as the WJ, so bare with me. Everything isn't going to be perfect the first time. Lol

2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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post #14 of 53 Old 06-14-2012, 01:40 PM
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Quote:
Originally Posted by Justin_WJ View Post
Everything isn't going to be perfect the first time. Lol
but will be for mine right.

~Aaron


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post #15 of 53 Old 06-14-2012, 01:45 PM Thread Starter
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Just some pictures of it all welded up, I'll post more when I do more bracing tonight, I'm gonna try to get the plate the winch sets on and the radiator armor on tonight as well. We'll see how it s gonna go.
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2000 WJ Limited, 4inch RC X, 242 T-case swap, 33x12.50 STT's, 15x8 D window wheels with 3.75 BS, JKS ADJ. Tracbar, T-case armor, Custom front winch bumper, Smittybilt XRC 8, 4.56's Extended Rola Rack w/Harbor Freight 6" lights, and always muddy :)
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