[DezertXj88]

So guys my Xj is on its way to be a mild ExPo vehicle. Its my DD, camping, fishing, ExPo rig..My original plan was to copy this here,
http://www.jeepforum.com/forum/f11/x...bumper-928227/
I hate big flashy bumpers..And I love hidden winchs. Clean, simple, lightweight and cheap.
Verus keeping the stock bumper, I pcked up a Warrior P# 560 bumper for 150 bones today with 2 new Hella 500 black magics on it. My idea is it will give more protection incase I needed to push something, or incase I bumped/hit something.
However when I went and picked it up I realized this bumper was not 3/16th like I was let to believe..its actually 3/16 bumper mounts and 1/8th formed bumper. So I'd like to beef up the Warrior a little because I do like it..ALOT, its got very very nice lines, matches well, just perfect in size and since I don't rock crawl or need to ram things..I think will a little added beef it'll do just fine!
Planning to reinforce it with 3/16 and do full bumper mounting/tie in brackets. Opinions on this? say 1/8th vs 3/16 reinforcement plates?


This is how it looks currently. Just 1/8 plate formed, completely hollow.



I want to add either 3/16 or 1/8 plates in it like this..

Full inserted into the bumper, and welded on both sides. Should I add gussets off the sides of these like the bumper mount idea? Or should I add in a plate to completely connect the 2 plates together?



For the corner, just add in a little gusset/brace..and one at the very bottom of the bumper.




And for the mounts, I'll be cutting the stock ones out and replacing them with full depth versions..they are currently 3/16, which is plenty strong, especially since I will be running the tie in brackets which have 9 bolts per side. However idk If I should do them like this, full depth and 2 gussets.

Or like this, full depth, 1/4" plate formed to bumper & 2 gussets




I was also curious on opinions/suggestion on Drings through the bumper. If I could, or it would be strong enough really...but run a Dring through the bumper, inbetween the 2 gussets, then weld it on the front of the bumper, weld it to the bumper mount and to the gussets?

The section inbetween the 2 bumper mounts will be untouched until the hidden winch comes, then I'll brace/cut & mod that to hide & hold a 12k Warn thats been sitting here.
Otherwise I'm basically looking for guidence, if my ideas good enough, if I should do something differently, add here or there, take away here or there? Whats your guys opinions, advice, suggestions?

Don't hate on my costco pizza board fab work

[BESRK]

I think I would probably just box it in from the mounting plates outward. Even with those ribs, a hard bump on the ends is gonna fold them in.. buckling the upper/lower parts of the bumper. Box in and then gusset to the mounting plates.

[Abaddon]

basicly do like the guy on CF was tring to say take some C channel and put it legs in and weld the legs to the bumper from the mounts out ward

it will box it in and kinda keep the weight down

[DezertXj88]

Originally Posted by Abaddon

basicly do like the guy on CF was tring to say take some C channel and put it legs in and weld the legs to the bumper from the mounts out ward

it will box it in and kinda keep the weight down

Do you have a link possibly? I've been looking but have found much yet!

[Spuznick242]

I think your going at it too complicated but that's just me. Have you thought about making it into an oba storage tank for the compressed air. I'm making a front bumber for my YJ right now with a very similar design made out of .125 steel plate. Couldn't telll you much about making what you have stronger other than to add more metal to it, and I wouldn't go anything thicker than .125 if it isn't going to be seeing much action since its just useless weight. But since your going a similar route as me, I think the air tank is the way to go.

[RenoF250]

I think I would get some 2x2" 3/8" wall square tube and weld it under the top flange. That would strengthen it quite a bit and be fairly easy. Probably weigh 30 pounds or so.

[webdog]

Originally Posted by BESRK

I think I would probably just box it in from the mounting plates outward. Even with those ribs, a hard bump on the ends is gonna fold them in.. buckling the upper/lower parts of the bumper. Box in and then gusset to the mounting plates.

x2

But I would use something a little stronger than cardboard!

[DezertXj88]

Originally Posted by webdog

x2

But I would use something a little stronger than cardboard!

Max I may be calling you..your work is top notch and I still have that stuff sitting here..maybe trade it to beef this bumper up slightly? Pm coming.

For air storage, I'm actually doing 2x6 rockers. Both will hold air..if my welds don't leak

[webdog]

Originally Posted by DezertXj88

Max I may be calling you..your work is top notch and I still have that stuff sitting here..maybe trade it to beef this bumper up slightly? Pm coming.

For air storage, I'm actually doing 2x6 rockers. Both will hold air..if my welds don't leak

sounds good, just let me know.

[Spuznick242]

Thats too much plumbing to do for both sides for air, I much rather just have one larger tank right up front close to my york and if anything just put a valve on each side near the front of the tire to tap into with a hose to fill up each side and easy of use for air tools.

[DezertXj88]

Originally Posted by Spuznick242

Thats too much plumbing to do for both sides for air, I much rather just have one larger tank right up front close to my york and if anything just put a valve on each side near the front of the tire to tap into with a hose to fill up each side and easy of use for air tools.

Ya didnt think of that...I'll probably use my passenger side as the air tank..using my sanden (sp?) for a compressor.

[dodger889]

With that compressor you will need to add an oiler, to keep the compressor alive. They are do not have their own oiling system in them.

[Spuznick242]

Originally Posted by dodger889

With that compressor you will need to add an oiler, to keep the compressor alive. They are do not have their own oiling system in them.

Best part of the York, its got a built in oiler and can be used with a higher rpm to make it fill faster, making a hand throttle my next upgrade after I hunt down my york.

[dodger889]

Originally Posted by Spuznick242

Best part of the York, its got a built in oiler and can be used with a higher rpm to make it fill faster, making a hand throttle my next upgrade after I hunt down my york.

Well sorta a york compressor is just an modified engine with reed valves in the head. So it has a crank case with oil in it. So it does not have a built in oiler per-say.

[Diamond-x]

Here's what I did:

http://www.jeepforum.com/forum/f11/t...build-1157408/