ZJ Front Bumper Build Thread - JeepForum.com

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post #1 of 53 Old 06-04-2008, 07:45 AM Thread Starter
jonzj
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1996 ZJ 
 
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ZJ Front Bumper Build Thread

I figured I would keep everyone up to date on my bumper build. I'll put up some more pictures as I get more stuff done to it.

http://i280.photobucket.com/albums/k...j/P1010083.jpg
http://i280.photobucket.com/albums/k...j/P1010084.jpg
http://i280.photobucket.com/albums/k...j/P1010086.jpg
http://i280.photobucket.com/albums/k...j/DSCI0427.jpg
http://i280.photobucket.com/albums/k...j/DSCI0426.jpg
http://i280.photobucket.com/albums/k...j/DSCI0429.jpg
http://i280.photobucket.com/albums/k...j/DSCI0428.jpg

The peice next to the driver side wheel well is a little off, but it's just tacked up so thats proably why it is a little off. The passenger side fits almost perfectly. I might put a tube brush guard on it later.


1996 ZJ,4.0L, 31x10.50 BFG AT's, IRO 3.5" Lift, Custom roof rack, Custom bumper

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post #2 of 53 Old 06-04-2008, 09:15 AM
Jebussaves0
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looks good so far!
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post #3 of 53 Old 06-04-2008, 09:51 AM
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Quote:
Originally Posted by jonzj View Post
I figured I would keep everyone up to date on my bumper build. I'll put up some more pictures as I get more stuff done to it.

http://i280.photobucket.com/albums/k...j/P1010083.jpg
http://i280.photobucket.com/albums/k...j/P1010084.jpg
http://i280.photobucket.com/albums/k...j/P1010086.jpg
http://i280.photobucket.com/albums/k...j/DSCI0427.jpg
http://i280.photobucket.com/albums/k...j/DSCI0426.jpg
http://i280.photobucket.com/albums/k...j/DSCI0429.jpg
http://i280.photobucket.com/albums/k...j/DSCI0428.jpg

The peice next to the driver side wheel well is a little off, but it's just tacked up so thats proably why it is a little off. The passenger side fits almost perfectly. I might put a tube brush guard on it later.
Looks good, I'll be interested to see the final product.
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post #4 of 53 Old 06-04-2008, 10:39 AM
Slawth
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Quote:
Originally Posted by jonzj View Post
I figured I would keep everyone up to date on my bumper build. I'll put up some more pictures as I get more stuff done to it.









The peice next to the driver side wheel well is a little off, but it's just tacked up so thats proably why it is a little off. The passenger side fits almost perfectly. I might put a tube brush guard on it later.
Holy gigantic images.
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post #5 of 53 Old 03-02-2009, 07:33 AM Thread Starter
jonzj
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I know its been a long time since I started last spring, but I've been real busy lately. The welders I've been using are my girlfriend's dad's, so I can only work on it when I go over to her house. His mig welder is also broken so that is one reason why I haven't been working on it. He does however have an old Miller 250 arc welder that I learned how to use. All of the welds have been from the arc welder. Here's some pictures of my welds:



This is the back side of the previous weld.








I'll get some more pictures up this weekend, hopefully it won't be snowing.

1996 ZJ,4.0L, 31x10.50 BFG AT's, IRO 3.5" Lift, Custom roof rack, Custom bumper

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post #6 of 53 Old 03-18-2009, 07:08 PM Thread Starter
jonzj
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I got a little more work done tonight. Its going pretty slow because I'm deciding to change things at the wrong time. Its alot harder to cut and drill when the pieces are put together, than when you can lay them flat on a bench.

Here's a pic of the fog light holes that I had to cut out with a cutoff wheel:


This is where a winch will go, if I decide to buy one in the future.

1996 ZJ,4.0L, 31x10.50 BFG AT's, IRO 3.5" Lift, Custom roof rack, Custom bumper

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post #7 of 53 Old 03-18-2009, 09:52 PM
FortCollinsZJ
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looks sweet. I like it.
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post #8 of 53 Old 03-24-2009, 09:14 AM
ISUzj
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crazy thought...would you be willing to share your Dimensions on that bad boy? I have been looking to build a front bumper now that I have a back one and this is one that I really admire.

What is the steel thickness?

I love how that thing is looking though, keep it up.

Can't wait to get started, but my wallet can......
~~~_______oooo_
~~ / ../...\...\_____\
~~[_---_____---_\-\\\\\\-\
~~~(o) )-o---(o) )-o---) )
94ZJ 5.2 Red; Rusty's 3" Coils,Skyjacker hydro's, Brush Guard, Custom Rear Bumper, Custom Roof Rack, KVG Quick Discos, 31-10.50-15's DAYTON TIMBERLINE A/T OBA 2 Gallon tank
Can't buy it? BUILD IT!! Do it cheap too cuz your in college

My Build Thread Align your jeep yourself B N B#175
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post #9 of 53 Old 03-24-2009, 03:40 PM Thread Starter
jonzj
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I appreciate it man, I've definitley put alot of time in it. It's basically just a winch "box" between the frame rails, with more pieces added to it. The center section is all 1/4", the front and side pieces are 3/16", and the top and bottom pieces are 1/8". I've got to get the rest of it welded up and then send it to the welding shop to add some clevis mounts. I will also put a winch guard hoop on it kind of like the Hanson bumpers have. I'll put some more pics up this weekend if I'm not kayaking. There's alot of rain coming my way.

1996 ZJ,4.0L, 31x10.50 BFG AT's, IRO 3.5" Lift, Custom roof rack, Custom bumper

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post #10 of 53 Old 03-30-2009, 07:35 PM Thread Starter
jonzj
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I've got everything welded up right now, except for the winch hoop, the light brackets, and the clevis mounts. I've still got to do some minor adjustments, but I think it is turning out pretty good for my first major project.







1996 ZJ,4.0L, 31x10.50 BFG AT's, IRO 3.5" Lift, Custom roof rack, Custom bumper

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post #11 of 53 Old 03-30-2009, 10:10 PM
ISUzj
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AWESOME~!!!!!!!! Me likey

Can't wait to get started, but my wallet can......
~~~_______oooo_
~~ / ../...\...\_____\
~~[_---_____---_\-\\\\\\-\
~~~(o) )-o---(o) )-o---) )
94ZJ 5.2 Red; Rusty's 3" Coils,Skyjacker hydro's, Brush Guard, Custom Rear Bumper, Custom Roof Rack, KVG Quick Discos, 31-10.50-15's DAYTON TIMBERLINE A/T OBA 2 Gallon tank
Can't buy it? BUILD IT!! Do it cheap too cuz your in college

My Build Thread Align your jeep yourself B N B#175
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post #12 of 53 Old 03-31-2009, 07:16 AM Thread Starter
jonzj
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Oh yeah, I'm pretty satisfied with it. It doesn't fit as good as I would like in some places, but what can I expect since I'm not a experienced fabricator. My roof rack didn't fit good at first, but I made it work. I guess you don't realize that something is not right untill its too late. :I've got a big date with a grinder ahead of me. I also need to get a carbide burr for my die grinder so I can smooth out the fog light holes. And I am very ready for it to be done and on my Jeep.

1996 ZJ,4.0L, 31x10.50 BFG AT's, IRO 3.5" Lift, Custom roof rack, Custom bumper

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post #13 of 53 Old 04-01-2009, 09:42 AM
spife7980
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at first i thought it was friggin ugly as crap but now that its coming along im really starting to dig it.

the one thing i would have done differently is to angle the front piece back/forward (bring the bottom toward the jeep) a smidge just so it isnt blatentely flat but its nothing really.

-James
Got to love an ORVIS guy...
IRO 5.5", Front LA & Double Sheer TB, Rear Adj SA and TB, JKS Quick Discos, Bilstein 5125, 265/75/16 Nitto Terra's, Cragar 16x& Soft 8s 4" bs
JCR Stage 2 Sliders, IRO Trans Skid, Carolina Drive shaft, IRO exhaust
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post #14 of 53 Old 04-01-2009, 11:59 AM
ISUzj
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so whats the plan, painting it black, POR15, Hurculine? What are you going to do for lights on the sides? How far does it stick out from the front part of the grille?

Sorry I sound Like a curious 4 year old. But I really want to build one like that for my jeep.

Can't wait to get started, but my wallet can......
~~~_______oooo_
~~ / ../...\...\_____\
~~[_---_____---_\-\\\\\\-\
~~~(o) )-o---(o) )-o---) )
94ZJ 5.2 Red; Rusty's 3" Coils,Skyjacker hydro's, Brush Guard, Custom Rear Bumper, Custom Roof Rack, KVG Quick Discos, 31-10.50-15's DAYTON TIMBERLINE A/T OBA 2 Gallon tank
Can't buy it? BUILD IT!! Do it cheap too cuz your in college

My Build Thread Align your jeep yourself B N B#175
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post #15 of 53 Old 04-01-2009, 02:51 PM Thread Starter
jonzj
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I'm probably going to paint it dark grey or gunmetal grey, and maybe repaint the cladding to match it. If that plan doesn't work out, I'll probably just paint it flat black with some Rustoleum enamel or something similar. I've got 3 sets of lights sitting in my closet waiting to be installed. 2 Hella 700FFs for the top of the bumper, 2 4" fog lights to go in the holes, and 2 narrow rectangular blueish colored fog lights to go in the bottom. You can almost see one of the holes on the bottom driver side. Both are cut I just need to finish the corners so I can get the metal out of the hole. It sticks out about 8" from the grill. The winch plate is 8"x30" or 32" I can't remember. I've got a pretty accurate Sketch-Up picture that I used to design it. It's not exact but it could give you a pretty good idea of the dimensions.

1996 ZJ,4.0L, 31x10.50 BFG AT's, IRO 3.5" Lift, Custom roof rack, Custom bumper

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