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Unread 03-08-2013, 10:44 PM   #1
dnjeep
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1976 CJ5 
 
Join Date: Feb 2012
Location: Deltona, FL
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My CJ5 Rear Bumper & Tire Carrier

I thought I would sit down & share how I went about building my rear bumper & swing out tire carrier. I stumbled upon a DIY bumper kit from Iron Scorpion, and decided to build one instead of purchasing a completed bumper that I would have to modify anyway in order to fit my cj5. I also decided to get their rear cross-member heavy duty support kit as well. Instructions (diagrams) on piece assembly are included with the kit.

Bumper kit (pic from their website):


Cross-member support kt (pic from their website):


Start of the build:

















Once the support pieces & the main pull-point bulkheads were fully welded and mounted together, I was then able to start fabricating the main body of the bumper.

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Unread 03-08-2013, 10:52 PM   #2
dnjeep
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I removed the gas tank in order to maximize the work area behind & around the cross-member. I figured this would help due to the fact that I knew I was going to be bolting & unbolting a lot......I was right. I do think though looking back on it that it would be possible to do this entire build without dropping the gas tank. I was just able to kill 2 birds with 1 stone; I was going to install new fuel lines & other things at the same time while I had the tank dropped.
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Unread 03-08-2013, 11:04 PM   #3
dnjeep
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A 3lb dead-blow hammer & large pipe wrench is all I used to encourage the metal where to go:





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Unread 03-09-2013, 03:00 PM   #4
dnjeep
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Ok, let's continue:




(The majority of time is spent test fitting/tack welding)










Now work commenses on the outer tappered corners (these areas took the most time and attention)




The most annoying part was that my welder kept tripping the breaker, so I never was able to do more than a 2"-3" continuous bead



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Unread 03-09-2013, 03:05 PM   #5
mat8828
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Thanks again for putting this up, this will be a project for me for sure.
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Unread 03-09-2013, 07:29 PM   #6
dnjeep
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No problem Matt, glad to.
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Unread 03-09-2013, 07:44 PM   #7
dnjeep
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Once the bumper was fully tack welded together, I worked on the spindle location & install for the swing-out tire carrier. I picked-up a heavy duty spindle from At o Z Fabrication here: http://www.atozfabrication.com/store/home.php?cat=263





After the spindle was tacked into place it was time to go over the entire bumper and fully weld every seam. Then the real "work" began......grinding, grinding, and more grinding.

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Unread 03-09-2013, 08:03 PM   #8
dnjeep
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After I pretty much made everything smooth it was now time to work on the swing-out tire carrier (adding the pull-point (clevis mounts) reinforcement pieces; two pieces sandwiching the first). I decided to use 2x3 & 2x2 tubing to fabricate the carrier.







After the main swing-out arm was welded-up, I could then mount the bumper and work on the rest of the carrier (location of tire and all). I was also able to relocate my back-up lights to the new bumper. I also got the tire carrier mounting plate & studs from A to Z Fabrication as well.











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Unread 03-09-2013, 08:23 PM   #9
dnjeep
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I used Duplicolor Bed Armor






















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Unread 03-11-2013, 09:51 PM   #10
dnjeep
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Here's how it looks today...now all I need is to decide on a spare.






I welded 2 chain links to the underside on either side of the receiver in order to hook the trailer chains.



I wanted to leave the main vertical support piece of the tire carrier open so I could add some accessories in the future (rack system that would go above the tire, hi-lift jack mount, etc...). I had to trim down a standard 2" hitch receiver cover in order for it to fit in the 1.75x1.75 opening of the 2x2 tubing. This will be used when the future accessories are not installed (I want the flexibility of not permanentally installing the rack & other items).

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Unread 03-11-2013, 11:03 PM   #11
rusty762
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bumper looks great, I built something similar to this for my 84 4runner. I am not a fan of this style of bumper for my current rig due to weight and loss of ground clearance/departure angle but I commend your building it yourself, turned out great!

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Unread 02-03-2015, 04:31 PM   #12
chopped50ford
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i looked up Iron Scorpion with no luck on the bumper kit, can you post information to get ahold of them.

I like the set-up, very clean and Sano...

thanks in advance
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Unread 02-03-2015, 04:57 PM   #13
JeepdaddyRC
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Holy cow! Awesome bumper! We used to use a "slam latch". How did you choose this latch? Are those 3/4 clevis mounts?
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Unread 02-03-2015, 06:52 PM   #14
mat8828
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Quote:
Originally Posted by chopped50ford
i looked up Iron Scorpion with no luck on the bumper kit, can you post information to get ahold of them. I like the set-up, very clean and Sano... thanks in advance
http://www.ironscorpion.com/zen/

Here's the link, I used their kit as well. It is an awesome design. Make sure and get the frame tie ins as well.
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Unread 02-04-2015, 04:55 PM   #15
chopped50ford
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Thank You, good link there
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