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Unread 11-28-2009, 09:35 AM   #16
LSRGreg
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2004 WJ 
 
Join Date: Jan 2009
Location: Tempe, AZ
Posts: 155
Finally was able to put some more hours in on this thing.

Here is what i have so far.. i have 3 concepts.. each with the winch in a different spot:

Here is #1: winch up top





Here is #2 winch below, and cut into factory sheet metal to move as far back as possible




And #3.. has winch low, but forward, and doesn't require any cutting of factory sheet metal


the lower mounted winch ones are able to keep the front of the bumper closer to body, but they loose approach angle, and can't really put a skid underneath without blocking all the air flow to lower part of radiator.. my favorite is #1.. here are some more shots:




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Unread 11-28-2009, 09:36 AM   #17
LSRGreg
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I think this is pretty much the final deal:



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Unread 11-28-2009, 09:37 AM   #18
LSRGreg
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Got the prototype bumper cut today. made it from chip board from an art store, and hard board from home depot.. here are some pics, and a link to the video of the winch mounting plate getting cut out..




support joint:

















I will be putting an angle on the end plates so they don't look so buldgey. I will bring in the front edge about 1" to 1.5"... to eliminate this weird looking corner:

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Unread 11-28-2009, 09:37 AM   #19
LSRGreg
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Here is the start of the fabrication i did today:





got the main parts tacked on the bench, then mounted it up to do the rest:















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Unread 11-28-2009, 09:38 AM   #20
LSRGreg
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here are the tow hooks partially welded:


Mounts:








I will have one of the guys TIG weld all of outside seams, and important welds. I suck with the TIG, and not quite good enough with a MIG welder.

Then i trimmed the sides with my sawzall when i got home:







Here is sneak peek of the lights...



Have a great Memorial Day!!
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Unread 11-28-2009, 09:39 AM   #21
LSRGreg
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some pics from memorial day weekend:




I got the lights mounted. I will end up modifying the cut out to fit a little better, since i can't use the OEM fog lights. they are too deep.



The way they are set up, they can be aimed down for close rock light type action, or pointed out for more of a fog and driving type action, depending on what you want to do. I went with the flood beams, for more close rock type action.. i think i am gunna upgrade the bulbs to HID ones, and see how they work. These lights are available in a spot or flood lens.

So i have a question.. for those of you that would consider buying this bumper, would you pay an extra $10 to $15 for shields that would close off the opening of the light, so you couldn't see the bolts like shown in this pic? Or just leave it as is? I really am not sure. Its a toss up for me.



Thanks!
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Unread 11-28-2009, 09:39 AM   #22
LSRGreg
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Got the last of the fabrication done today, and got it all mounted back on there for some testing. Also got the winch wired up. I am going to try to make it to GSW next weekend.







These tow hook welds are over 1/2" wide done with a TIG.. they are going anywhere!












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Unread 11-28-2009, 09:40 AM   #23
LSRGreg
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I was able to do some testing with the new bumper using a forklift yesterday.. results are perfect..





this one is just one fork right in the middle of the lower radiator support:



Pass side lift:



Driver side lift:



zero deflection with fork lifting on back edge:







D-ring test with my tree saver:

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Unread 11-28-2009, 09:42 AM   #24
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Mine is finally finished.. im very happy with how this sucker turned out!













the HID fogs lit up:







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Unread 11-28-2009, 09:43 AM   #25
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Here are a couple pics from Moab:





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Unread 11-28-2009, 09:43 AM   #26
LSRGreg
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I got the in cab winch control wired up and mounted...

12voltguy.com is awesome. One of the terminals on the switch broke, not sure if happened in shipping, or if i did it during install, so i asked him how much for one of the replacement push button switches and he sent me out another one for free no questions asked, and i got it in a few days! Plus it was already soldered with the terminals! Great Service! I highly recommend him for your switch panel needs!



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Unread 11-28-2009, 09:44 AM   #27
LSRGreg
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i found out that my upper control arm bushings on the front axle were pretty much toast. When backing up, and applying the brakes, i could feel the front axle move.

So i scored up some Johnny Joints, and replaced the drivers side. The passenger side will get changed when i make a front truss.

See how shot they were:


since they were so worn out, my caster was off a huge amount because the axle was twisted pretty far forward..



Here is the new joint after i pressed it in:



The front end feels much more solid now. But i still need to score some stiffer bushings for my track bar to get rid of the slight wiggle i have.

G-
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Unread 11-28-2009, 09:44 AM   #28
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I got my 2" coil spacers mounted up front today. The dub finally sits level now, and rides nicer because it doesn't feel like its going to endo into bumps. Feels much more balanced.







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Unread 11-28-2009, 09:45 AM   #29
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Got my Kevin's Offroad Steering Stabilizer installed:

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Unread 11-28-2009, 09:46 AM   #30
LSRGreg
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Hit up sedona last weekend for a little mtn biking, and wheelin.. Saturday it poured on us right in the middle of our ride, so we had to wait out the rain under a cliff ledge. I have never gotten so wet without being completely submerged in water. Good times.. so later that day, we hit up Broken Arrow, then Sunday morning did Soldiers Pass.













Going down Broken Arrow....



Then back up.. even in the rain..



Then nice and Sunny on Soldiers Pass:

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