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Stainless Steel Door Hinge PinsPoly Door Hinge BushingsDisc Brake Kits from ECGS

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Unread 06-02-2012, 02:12 PM   #1
04WJny
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Bumper and Tire Carrier Build

After i saw the writeup that BESRK did, i really wanted to build my own bumper and tire carrier for my YJ. I finally decided to buy some steel and supplies a few days ago and picked up all my steel for $140 which includes:

6' of 2"x4" rectangular tube with 3/16" wall
6' of 2"x2" square tube with 1/8" wall or 11Ga
4' of 2"x3" rectangular tube with 1/8" wall or 11Ga
2' of 3/8"x3" flat steel bar


Along with that I purchased the tire carrier spindle and 3/4" d ring shackle mounts off of AtoZfabrication for about $86 including shipping. And got some smittybilt 3/4" shackles off of 4wd for $12 a piece.

Bumper Clevis mounts (AtoZfabrication.com)


Tire Carrier Swingout Heavy Duty Hinge Kit (AtoZfabrication.com)



Two nights ago i made the mounts that attach the bumper to the frame. Those were made by cutting the 2' of 3/8"x3" flat steel bar into 2 10" lengths and drilled 4 holes center to center 7.875" by 1.125"
I then cut 2, 1.75" lengths of the 4"x2" rectangular tube and centered it on the mounts

The mounts after being cleaned and tacked:



I cut the 2"x4"x3/16" rectangular tube to 55" in length with the horizontal band saw and cut the corners with my 4.5" cutoff wheel to give it some style. I used the remaining 2"x4" rectangular tube to cut 2" strips so that i can cap off the ends of the bumper.

This is what it looked like when i finished cutting one of the ends :



More pics to come soon!

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1987 YJ I6 4.2L Weber 34 DGEC carb, 4in RC, Custom 1 inch BL,Custom Steering box skid, homemade rear bumper with tire carrier, 33x12.5x15 KM2's on
Cragar Soft 8's, and a few other things
In the process of putting in an 8.8, d30, 4.10's, SOA, and a homemade belly up skid
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Unread 06-02-2012, 03:43 PM   #2
wushaw
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Looks good

Mine are also Besrk knock offs.
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Unread 06-04-2012, 03:15 PM   #3
04WJny
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Drew up come CAD/Autodesk Inventor Drawings:






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2004 WJ I6 4.0L DD
1987 YJ I6 4.2L Weber 34 DGEC carb, 4in RC, Custom 1 inch BL,Custom Steering box skid, homemade rear bumper with tire carrier, 33x12.5x15 KM2's on
Cragar Soft 8's, and a few other things
In the process of putting in an 8.8, d30, 4.10's, SOA, and a homemade belly up skid
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Unread 06-05-2012, 10:52 PM   #4
04WJny
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Got some work done yesterday but never got a chance to get some pics. Yesterday i got part of the swingout cut and tacked along with capping the ends on the bumper.




If you dont have access to some 3/16 steel plate, the ends can be capped by cutting some of the 2x4x3/16 tube into 1 7/8" wide strips with the angle grinder and sanding them until their to size. I however had some 3/16 plate laying around at work so used that.

Tomorrow i will use the mill at work to cut the hole for the 1.25" spindle with a 1/25" endmill. I will also use a 1/4" drill to cut the corners in the slots where the D ring mounts will be and cut them with a 1/4" endmill. I also picked up a 2" receiver from harbor freight and plan on adding it in the center of the bumper; i will cut the square hole the same way i will cut the holes for the d ring mounts. If i dont run out of time ill make a gusset for the tire carrier part and also make a mounting plate for the tire out of some 1/4" plate and tack some 1/2-20 bolts through instead of using studs
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2004 WJ I6 4.0L DD
1987 YJ I6 4.2L Weber 34 DGEC carb, 4in RC, Custom 1 inch BL,Custom Steering box skid, homemade rear bumper with tire carrier, 33x12.5x15 KM2's on
Cragar Soft 8's, and a few other things
In the process of putting in an 8.8, d30, 4.10's, SOA, and a homemade belly up skid
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Unread 06-06-2012, 04:25 AM   #5
monkers
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looking good!!! keep the pictures coming......
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Unread 06-07-2012, 11:26 AM   #6
04WJny
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Thanks! Change of plans... I didnt use the mill at work to cut the square holes for the hitch receiver tube and d ring shackle mount; instead, i measured the radius on the outside of the receiver tube (3/8" radius) and drilled a 3/4" thru hole in the corners using the drill press. i then drew tangent lines connecting the outside edges of each circle so that i had the same shape as the reciever tube, and cut the lines with a 2" cutoff wheel. I did the same thing to the shackle mounts too but i drilled the holes with a 1/4" bit. the only difference is that i had to put a 1/8" radius on the shackle mount so that the corners would fit in no problem. Ill get some pics up asap so you know what i mean.
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2004 WJ I6 4.0L DD
1987 YJ I6 4.2L Weber 34 DGEC carb, 4in RC, Custom 1 inch BL,Custom Steering box skid, homemade rear bumper with tire carrier, 33x12.5x15 KM2's on
Cragar Soft 8's, and a few other things
In the process of putting in an 8.8, d30, 4.10's, SOA, and a homemade belly up skid
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Unread 06-08-2012, 04:14 AM   #7
monkers
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More than one way to skin a cat!! Lots of guys build stuff without mills....I will drill holes like you did and use a torch, or jig saw, grinder, whatever method works. I do not have a plasma cutter, so its torch and grind.
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Unread 06-08-2012, 05:20 AM   #8
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Awesome
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Ask about my Custom Paracord Jeep Stuff!!
Door straps, rollbar grab handles, bracelets.

[url]www.SkippyKustoms.com[/url]
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Unread 06-08-2012, 10:55 AM   #9
04WJny
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Ive also decided that i want to tie in the bumper into the frame. ill do that by using some of the leftover 2x4x3/16" 2.5 or so inch length steel tube and cutting it diagonally to make it L shaped to fit on the front side of the crossmember and drill into the frame. I also decided to change the way I mount my latch, it will look more like how the LOD latch is positioned.

In this pic i have the mounting feet clamped to the 2x3 peice of steel just to hold it into the correct position so it will fit the bolt pattern in the frame. I also have the d ring shackle mounts and 2" reciever tube from harbor freight tacked in to position:



In this pic i also tacked the back of the shackle mount to the bumper and left enough space to weld the mounting feet into place:
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2004 WJ I6 4.0L DD
1987 YJ I6 4.2L Weber 34 DGEC carb, 4in RC, Custom 1 inch BL,Custom Steering box skid, homemade rear bumper with tire carrier, 33x12.5x15 KM2's on
Cragar Soft 8's, and a few other things
In the process of putting in an 8.8, d30, 4.10's, SOA, and a homemade belly up skid
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Unread 06-11-2012, 10:49 PM   #10
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Got alot of the welding done today. i welded both d ring mounts front and back, the receiver tube for the hitch front and back, the end caps were welded too, and i welded the mounting feet on the side closest to the frame and tacked the side near the bumper to make sure it will fit on my jeep. I TIG welded everything with a Miller Dynasty 200 with 3/32 tungsten, size 8 cup, at appx. 180 amps, using 1/8" filler rod

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2004 WJ I6 4.0L DD
1987 YJ I6 4.2L Weber 34 DGEC carb, 4in RC, Custom 1 inch BL,Custom Steering box skid, homemade rear bumper with tire carrier, 33x12.5x15 KM2's on
Cragar Soft 8's, and a few other things
In the process of putting in an 8.8, d30, 4.10's, SOA, and a homemade belly up skid
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Unread 06-12-2012, 10:34 AM   #11
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Looking good
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Unread 06-12-2012, 10:21 PM   #12
04WJny
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Welded the tire carrier part today except for the 2x3 tube that mounts to the spindle because i have to cut the 2.25" radius. This time i used 110-120 Amps with 3/32 tungsten and 1/16" filler to weld the .120 wall 1018 steel.


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2004 WJ I6 4.0L DD
1987 YJ I6 4.2L Weber 34 DGEC carb, 4in RC, Custom 1 inch BL,Custom Steering box skid, homemade rear bumper with tire carrier, 33x12.5x15 KM2's on
Cragar Soft 8's, and a few other things
In the process of putting in an 8.8, d30, 4.10's, SOA, and a homemade belly up skid
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Unread 06-13-2012, 01:37 AM   #13
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hope the ends of those three pieces are still where they need to be. finish welding before tacking everything together can make them wander a bit.
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Unread 06-13-2012, 04:34 AM   #14
monkers
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Looking good!! I have a question on the AtoZ spindle. How long is the portion or the stub that extends through the bumper? Just wondering for when I build mine, curious how much length there is to put in the bumper. Thanks
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Unread 06-13-2012, 05:40 AM   #15
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Quote:
Originally Posted by fratis View Post
hope the ends of those three pieces are still where they need to be. finish welding before tacking everything together can make them wander a bit.
Agreed... I'd definately recommend tacking/welding the "A" frame to the main swingarm before welding the swingarm to the pivot tube. Normally, welding the "A" frame onto the arm will pull it up on both ends.


Bumper looks great so far.. now get back to work!!
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