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BDS 4-1/2" Suspension Lift Kit - Jeep Wrangler YJRuffstuff 10 year saleRough Country Lift Kits and Parts!

Unread 12-14-2010, 12:54 AM   #1
Registered User
1992 XJ Cherokee 
Join Date: May 2010
Location: MI
Posts: 99
XJ Front Bumper Plans

Hey Guys,

I have always wanted a functional cool looking rock bumper on my 1992 Cherokee Limited. But they are too expensive. so My brother has decided to buy a welder for multiple reasons, and i need some plans/measurements/advice on welding up my own set of bumpers.
i want to keep it kinda simple and cheap.

i was thinking this for the front:
Olympic 4x4 Products 533-151 - Olympic Rock Front Bumper with Hitch for 84-01 Jeep® Cherokee XJ - Quadratec

and this for the rear:
Garvin Industries 34800 - Garvin Industries Rear EXT Series Swing Away Tire Carrier Bumper System for 84-01 Jeep® Cherokee XJ - Quadratec

If anyone has done something like this before, please chime in! I mainly want to have hitches front and rear for a future winch mounted on a hitch reciever

1992 Jeep Cherokee Limited 4.0l HO [Brand New Rebuilt by ATK]
Dana 30 [front] & Dana 35c [Rear], 4 Speed Automatic, Selec Trac Transfercase
3" Rough Country Lift, IRO Double-shear Track Bar, JKS Discos,
Michellin 31X10.5XR15
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Unread 12-14-2010, 12:59 AM   #2
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1998 XJ Cherokee 
Join Date: Jun 2009
Location: Union County Nj/ East Stroudsburg Pa
Posts: 518
look here for some ideas if you plan on recovering make sure you look at the jcr tie in brackets and make something similiar.
www.rigidco.com Jeep Cherokee XJ Offroad Bumpers, Rocker Panel Guards & Vehicle Armor
JcrOffroad, Inc.
98 Green Cherokee Classic 4.0
3'' Rough Country II 33x12 bfg at
Spring Break Build thread/ makeover
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Unread 12-14-2010, 04:53 PM   #3
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1979 J-Series Truck 
Join Date: Jan 2010
Location: Portland, OR
Posts: 57
Well, if you have a welder, you are off to a good start. If you don't already have these, get them:

Angle grinder - get at least 1 good one. You'll use this tool SOOO much.
Good corded 1/2" Drill - Again don't get a cheap one, a nice one will last you years and years
Drill bits - Either go with a nice set of Black Oxide ones or Cobalt.
Jig Saw w/ metal blades

With these tools you can fab most things.

Use cardboard cut outs to mock up your pieces. If you want something more rigid, and if you have access to it, use scrap sheet metal or aluminum.

As far as ideas for the bumper:
Use Tube - sure they may not look as cool as some of the plate ones, but they are easy to build and super strong. I would go with a 2" x 5" or 2" x 6" with 1/8"-1/4" Wall

Through Tube Shackle Tabs - don't be lazy and weld your shackle tabs to the front surface of your bumper. Any lateral load on the tab will pull it off. Cut a hole through your tube on both sides and weld that sucker in so it won't go anywhere.

Tie in brackets - Don't only mount your bumper to the stock mounting location. Go all the way back and grab the bolts for the steering box. The JCR tie-in plates as mentioned above by Green4dr are perfect

Here are some drawings of my winch bumper

The large green piece is the stock front crossmember. You can see how many bolts hold it in place to the uniframe

The smaller green pieces help protect the the uniframe from crushing by spreading the load out

Here is a shot of almost what it turned out to be

Here it is finished and in use. I added a small hoop (wish I had made it bigger to I could actually see it from inside...)

I can't afford a winch yet, so I use it as a place to hold...stuff


[FONT="Comic Sans MS"]"Working with cars is a little like a really awesome date: you start out expecting this to be simple and straightforward; four hours later you're laying under her, panting and cursing, and things are a lot more complicated than you thought."[/FONT]

[B][FONT="Tahoma"][SIZE="3"]I [U]drove[/U] [/SIZE][SIZE="4"][COLOR="White"]okee[/COLOR][/SIZE][/FONT][/B] ('92 XJ)
then I wrecked him...
So Then...
[B][FONT="Tahoma"][SIZE="3"]I [U]drove[/U] [/SIZE][SIZE="4"][COLOR="Red"]r[/COLOR]okee[/SIZE][/FONT][/B] ('93 XJ)
then I rolled him...
[B][FONT="Tahoma"][SIZE="3"]I drive [/SIZE][SIZE="4"][COLOR="Red"] Clifford[/COLOR][/SIZE][/FONT][/B] ('79 J-20)
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Unread 12-14-2010, 05:36 PM   #4
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2015 JK Wrangler 
Join Date: Dec 2003
Location: Flourtown, PA | Bethany, DE
Posts: 1,050
I LOVED my OR-Fab bumper - so much so I ran it on both my XJ's! I hate tube bumpers but I beat the piss out of them and they held up great!

Shots of my other XJ are blocked here at work so I can't link it
-Quadratec Live Chat Rep.
-Please contact us at user ID "Quadratec" with any Sales or CS questions. You can also contact Sales at 1-800-745-2348 or Customer Service at 1-800-745-6037
-The statements in this message do not necessarily reflect the opinions of Quadratec, Inc.

-98 ZJ Limited 5.9L - 4.5" lift, 32" Mickey Thompson MTZ's, Tomken rocker guards, D44 rear, 3.73's, LSD, 4xDoctor D30 guard, custom projector HID headlights, custom intake, LED lightbar, underdrive pulley, trans vent tube - Wheeler/Bad Weather Rig
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Unread 06-20-2013, 08:41 AM   #5
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Join Date: Feb 2013
Location: Bursa, Nilufer
Posts: 2
is it possible to share these 3D's with me?
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bumper build , xj

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