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Unread 06-27-2013, 12:51 PM   #1
demlock
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2009 JK Wrangler 
 
Join Date: Mar 2013
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Custom Fabricated Hoop Stinger Bumper

Some buddies of mine just started a small fabrication shop in Chandler. Like most start up business its based out of the garage to save on overhead (in turn allows for lower pricing too). Here is a photo shoot of the bumper I had them build for me over the past weekend. Enjoy!

Picking up the materials for the build. All 100% American made steel will be used in this build ... Except for the Chinese D-Rings



The shop being used for the build. Yes, its a garage but the quality came out fantastic as you will see later on.


Pictures of the bumper that is being replaced shortly ...




Let the fabricating begin!





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Unread 06-27-2013, 12:54 PM   #2
demlock
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Welding in place the new winch plate using a Snap On MIG unit. I am returning Saturday to finalize the winch mount (figured it needs more support to function safely).





Building the bumper's base ...




Attaching the lower skid plate to the bumper's base
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Unread 06-27-2013, 12:54 PM   #3
demlock
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Creating the bumper's end caps comes next ...



One overall shot the bumper so far


Preparing to attach a set of D-rings


One of my personal favorites...the recessed winch fair lead!


Finally starting the tube bending process (following morning)



Initial Hoop finished and tacked on
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Unread 06-27-2013, 12:55 PM   #4
demlock
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The stinger is now attached but awaiting the support brackets


Supports brackets now attached to the hoop and stinger



Shot from the inside...please ignore the bug splatters!


So whats next for this bumper?
  • Recessing a Rigid Industries 20" LED Light bar (once funding allows) into the bumper.
  • Debating between Raptor liner or powder coating

Whats next for the Jeep?
  • Custom fabricated tube fenders
  • Custom fabricated rear bumper
  • Custom fabricated rock sliders
  • All will feature unique tube styling!
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Unread 06-27-2013, 12:56 PM   #5
demlock
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Ready for paint!

Sorry, I forget to get pictures of the primer stage...

Bed liner is on! I figure it may chip off easy but a can of Rustoleum only costs about $7 for touch ups.


'
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Unread 06-27-2013, 08:30 PM   #6
Carlos14
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One of the better looking JK bumpers I've seen, nice job!
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Unread 06-28-2013, 12:31 AM   #7
AtTheHelm
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Good job!

How did you do the recessed fairlead?

Why d-rings instead of shackle mounts?
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Unread 06-28-2013, 08:44 AM   #8
BESRK
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Nice! I like that integrated fairlead.. slick.
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Unread 06-28-2013, 05:35 PM   #9
BCrawford64
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Love that ranger and custom bumper. But I really hate those jeep fenders lol. Please do something cool with them and post it on here.
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Unread 06-30-2013, 08:41 AM   #10
rchase559
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Definitely like the recessed fair lead but I really hope it is smoothed out more before you use it.

I'm also curious why you/they used trailer hold downs for recovery points.
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Unread 07-01-2013, 11:35 AM   #11
demlock
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Quote:
Originally Posted by AtTheHelm View Post
Good job!

How did you do the recessed fairlead?

Why d-rings instead of shackle mounts?
I did the recessed fair lead by welding the fair lead on the inside of the bumper then smoothing the two surfaces together.

Quote:
Originally Posted by BCrawford64 View Post
Love that ranger and custom bumper. But I really hate those jeep fenders lol. Please do something cool with them and post it on here.
I hate the fenders too! I plan to do a custom set of flat fenders that incorporate tubes in the future. I would estimate this project to be about two months out. First I need to finish my rear bumper and suspension.

Quote:
Originally Posted by rchase559 View Post
Definitely like the recessed fair lead but I really hope it is smoothed out more before you use it.

I'm also curious why you/they used trailer hold downs for recovery points.
The fair lead is 100% smooth. If you run your finger down the fair lead it feels like glass. Not a single thing to catch the line.

I liked the look of the trailer hold downs better personally. Some have expressed them as a safety concern but the more I think about it they should be safe. The hold downs are rated for 20,000 pounds and are welded top and bottom plus on the sides. Before they break off you will see damage to the grade 8 hardware mounting it in place.
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Unread 07-05-2013, 03:45 PM   #12
fratis
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looks great. The grill hoop looks perfect.

The tick-tack weld is fine but might want to overlap a bit more and cover the crater. I nudge it back a hair before starting the next tack.

The D rings are totally fine. I hope you didnt tick-tack those on though.

Im not a safety nazi but wear a face shield along with the safety glasses. Just went back in last week to have a piece of metal dug out of my eye for the second time. They have to scrape your eyeball and then polish it with what looks like a mini wire-wheel grinder. Of course you are forced to watch the process the whole time. Nothing like a kidney stone but still sucks. I was wearing safety glasses both times. The trick to getting yourself to wear a face shield is to keep it nice. Once it gets cloudy it comes off. Ive also had a 3/4" long wire imbedded in my neck (wire wheel). It was so deep i didnt know for 6 months until it started getting very weird.
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Unread 07-11-2013, 12:28 AM   #13
WranglerRouser
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Sweet build!
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Unread 07-22-2013, 12:58 AM   #14
karlo
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Looks good! I really like the design of your bumper/stinger.
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Unread 07-24-2013, 12:14 PM   #15
demlock
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Quote:
Originally Posted by fratis View Post
looks great. The grill hoop looks perfect.

The tick-tack weld is fine but might want to overlap a bit more and cover the crater. I nudge it back a hair before starting the next tack.
Everything is welded top / bottom if possible and at least welded top. Nothing was left finalized in the tick-tack method.

The D rings are totally fine. I hope you didnt tick-tack those on though.
The D rings are welded fully around, no tick-tacks.

Im not a safety nazi but wear a face shield along with the safety glasses. Just went back in last week to have a piece of metal dug out of my eye for the second time. They have to scrape your eyeball and then polish it with what looks like a mini wire-wheel grinder. Of course you are forced to watch the process the whole time. Nothing like a kidney stone but still sucks. I was wearing safety glasses both times. The trick to getting yourself to wear a face shield is to keep it nice. Once it gets cloudy it comes off. Ive also had a 3/4" long wire imbedded in my neck (wire wheel). It was so deep i didnt know for 6 months until it started getting very weird.
I am not in any of the photos. When welding he wore a full face shield but cutting was a different story. At all times why both wore glasses that fully covered the eyes but never a full face mask. I do agree however that safety should be a primary concern.

Quote:
Originally Posted by WranglerRouser View Post
Sweet build!
Thanks!
Quote:
Originally Posted by karlo View Post
Looks good! I really like the design of your bumper/stinger.
Thanks!
The rear bumper and tire carrier had gotten delayed due to actual customers. Unfortunately when your only paying for parts your not at the top of priorities...

We are looking to incorporate a stinger type design into the rear bumper to help pull everything together. After the tire carrier I will be returning for arched fenders followed by rock sliders.
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