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Unread 10-12-2012, 07:02 AM   #1
2000-TJ
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TJ rear bumper build

I started building a rear bumper for my 2000 TJ yesterday. Heres the materials I bought.

6' of 2"x4"x1/4" tube $41.57
6' of 1"x1"x1/8" tube $10.38
2' of 2 1/2'x2 1/2"x1/4" tube $12.14
4' of 1/4" Angle iron
3' of 1/4" channel
Bought both the angle and channel as scrap @ 0.40 cents a lb and came to a total of $5.60 I wish they had it all in scrap prices!

Total: $71.69

I know I wont need all of this but I always like to buy more than I need when I build something that I have never built.

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Unread 10-12-2012, 07:03 AM   #2
2000-TJ
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This is what I removed. These Items are for sale PM me for details.
038.jpg  
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Unread 10-12-2012, 07:04 AM   #3
2000-TJ
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I plan to get alot further on it today so I can post some progress.
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Unread 10-12-2012, 09:02 AM   #4
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So I got busy this mornin and started out by cutting the 2x4 tube to 55 inches in length and cut a triangle out of each end with a sawzall man I really need some tanks for my torch set or a plasma cutter but I make due.
054.jpg   055.jpg   057.jpg   059.jpg   060.jpg  

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Unread 10-12-2012, 09:04 AM   #5
2000-TJ
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Then I clamped the ends and did some welding with my trusty Hobart TigMate.
061.jpg   063.jpg   066.jpg  
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Unread 10-12-2012, 09:07 AM   #6
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And did some grinding to smooth the welds.
061.jpg   063.jpg   067.jpg   068.jpg   065.jpg  

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Unread 10-12-2012, 09:10 AM   #7
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I had some uneven ends after welding and grinding so I squared them up with the chop saw.
070.jpg   071.jpg  
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Unread 10-12-2012, 09:16 AM   #8
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It ended up being 53 inches Because I didnt figure for having to square up the ends so it is 2 inches shorter than I had pland but I checked it and it will still work out good its 2 inches short of being as wide as the jeep but I will split the differance 1 inch on each side shouldnt matter.
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Unread 10-12-2012, 12:53 PM   #9
jasonswelding
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If the 2 1/2" tube is for a receiver, test fit a hitch in it. The seem on the inside may cause it to be to tight.
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Unread 10-12-2012, 04:06 PM   #10
BESRK
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You can take a file to the seam to smooth it down. Even so, the 1/4" wall receiver tube is gonna be a tight fit. Actual receiver tube is run over a mandrel to get the proper size.

Are you certain about the 53" length? I make my bumpers 58" wide and they're about 1" shy of the edge of the tub. Doesn't make a big difference if you're not going to run a swingarm. However if you do run a swingarm, the shorter length will make it difficult to place your pivot spindle and latch "outboard" of the tailgate (especially with the tapered bumper ends).
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Unread 10-12-2012, 04:15 PM   #11
2000-TJ
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Quote:
Originally Posted by jasonswelding View Post
If the 2 1/2" tube is for a receiver, test fit a hitch in it. The seem on the inside may cause it to be to tight.
I already tested it and it works.
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Unread 10-12-2012, 04:17 PM   #12
2000-TJ
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Quote:
Originally Posted by BESRK View Post
You can take a file to the seam to smooth it down. Even so, the 1/4" wall receiver tube is gonna be a tight fit. Actual receiver tube is run over a mandrel to get the proper size.

Are you certain about the 53" length? I make my bumpers 58" wide and they're about 1" shy of the edge of the tub. Doesn't make a big difference if you're not going to run a swingarm. However if you do run a swingarm, the shorter length will make it difficult to place your pivot spindle and latch "outboard" of the tailgate (especially with the tapered bumper ends).
I will check it again tomorrow but I think it'll be fine 55 is the width of the tub so 53 should be ok
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Unread 10-12-2012, 06:03 PM   #13
sailsurf7713
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Looks good so far. I just started a rear crossmember and paid 67 dollars for 4x2x3/16" x 6' And had to order it online!
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Unread 10-13-2012, 05:37 AM   #14
2000-TJ
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yeah the place I get material from has the best prices I have ever seen only thing is they keep it outside so it gets a little rusty. but I can live with that for the prices !
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Unread 10-13-2012, 06:16 AM   #15
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Love it man. Can't beat saying you but your own bumper nevermind saving hundreds of dollars

Sent from my iPhone while under my Jeep
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