Bumper Build || Next Stage

C2U5H · 03-31-2009, 07:20 PM

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Results Pages (to find the finished projects):
- Aux. Fuse Box Mounting - Page 1, post #4
- Front Bumper & 7" HID lights - Page 2, post #25
- Race Trim Off-Road Suspension Seats - Page 4, post #54 & 55
- Viair 100% Duty Cycle OBA System - Page 5, post #63
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I'll be posting write-ups and such as I go along, but I'm going to tackle the next stage of my TJ's life soon. The plans for this summer are, in order in which they're planned:

Front bumper build (1/8" plate and 2.25" x 0.120" wall tubing)
Two 7" HID off-road lights
Twelve circuit aux. fuse box & ground strip
OBA system
Re-wire entire aux. electrical system (aux. reverse lights, offroad lights, headlights, amplifier, compressor)
Rocker guard build (3/16" plate and 2" tubing)
Rear bumper & swing-out tire carrier build (2x4x3/16" rectangular tubing, 2x2x3/16" square tubing)
Ford 8.8 swap (w/LSD)
3-4" LA lift, TT, SYE, DS
Re-gear to 4.88 and lock axles + 35" MTs

Haven't gotten too far yet, but have got the basic layout of the front bumper done ... I'm welding up the driver's side tonight. Whaddaya think? (Obviously it's a cardboard mock-up)

I also got the two 7" HID off-road lights and the Blue-Sea Systems' 12-circuit aux. fuse box in the mail today. The lights seem very well built and were packaged nicer than most packages ... and I tested them ... they're bright as hell.

all3forus · 03-31-2009, 07:28 PM

Great start...Can't wait to see it finished...

jeff83 · 03-31-2009, 07:30 PM

yeah welding cardboard might result in some fire? I think

just kidding real nice start though

C2U5H · 04-04-2009, 07:23 PM

Got some work done today!

Got the driver's side of the bumper almost done. I just have to cap off the backside so it looks nice. So far I just need to do the passenger's side, add the two gussets/supports for the inside ... they will also be the support/backing plate for the shackles.

And I also made a bracket for my Blue Sea 12-circuit fuse box ... I thought of a couple of different mounting locations and found that right above the battery has the most wasted space. The bracket attaches to the two batter hold-downs and is stout. I built the bracket with a slight slope so any water that may get into the fuse box will drain out. The bracket's easily removable: just the two bolts--you'll be removing them anyway to get the battery out.

And finally, day one of my two-day wrenching weekend was a maintenance item: new radiator, upper & lower hoses, cap, thermostat, thermostat gasket, and serpentine belt. No more belt squeak, no more coolant puddles in the driveway.

prd_cdn · 04-04-2009, 10:51 PM

VERY COOL Idea and I agree the space above is a huge waste of space.. good use of it!! my plans exactly !!!

C2U5H · 04-06-2009, 06:09 PM

Got the other side welded up and test fit!!

Still need to do some finish grinding, add the winch guard, inner supports/gussets, and the shackle mounts.

I've learned a lot while doing this ... like 1/8" plate doesn't give like cardboard so measurements have to be dead-on, LOL. Live and learn, and that's why I wanted to make this.

I made this by just looking at a bunch of pictures of plate bumpers and taking attributes I liked. I wanted it to be unique ... so I went with 1/8" plate instead of 2x4" rectangular tubing with tapered ends. I needed something that doesn't catch on every rock at Rausch Creek, and won't limit tire travel when I go 35's. I wanted the winch to appear to be sunk down and also wanted some fender protection, but not as much as a full-width bumper. So mine's sort of a assimilation of all that with a mid-stubby width.

All done with a hand drill, my Hobart Handler 140, and a 4-1/2 angle grinder. And some Magic Hat #9.

C2U5H · 04-06-2009, 06:19 PM

In retrospect, things I may incorporate into the front bumper (other than the aforementioned shackle mounts, winch guard, and inner supports):

- Extend the top plate back to the grill (sway-bar will mount on top of it, only raising it 3/16")
- Make a steering box skid plate that bolts onto the bumper

Comments and questions welcome! And any suggestions you think would help at this stage of the build is, of course, encouraged.

JESSETHELJ · 04-06-2009, 06:23 PM

Nice Job. That Hobart 140 is a champ. I stated off making my tube doors first. Rocker panels will be next after i get the plasma cutter. So i look forward to your rocker build. With your bumper any chance I could get a rear shot from the back?

I do think it would be a great idea extending the top plate all the way back. Looks so clean. Did you do one side at a time or did you cut both sides at once.

C2U5H · 04-06-2009, 06:33 PM

Quote:

Originally Posted by JESSETHELJ

Nice Job. That Hobart 140 is a champ. I stated off making my tube doors first. Rocker panels will be next after i get the plasma cutter. So i look forward to your rocker build. With your bumper any chance I could get a rear shot from the back?

I do think it would be a great idea extending the top plate all the way back. Looks so clean. Did you do one side at a time or did you cut both sides at once.

Sure, next time I take pics (which will be when the shackles and winch gaurd are added later this week) you can count on a rear shot.

I did one side at a time ... pretty much every piece had to be ground-down to fit. Not to exact with cardboard, a marker, and 4-1/2 cut-off wheels, LOL. All fun, though. I just thought it was easier to do one side, then compare the other side's pieces to the completed one to get them looking the same.

**Apex** · 04-06-2009, 06:42 PM

Hope you don't ever consider an Anti-rock, otherwise very nice build

C2U5H · 04-06-2009, 06:57 PM

Quote:

Originally Posted by Jeep02Apex

Hope you don't ever consider an Anti-rock, otherwise very nice build

You know I was thinking that. Nothing a little grinding action wouldn't correct ... those systems don't really stick out a couple inches farther then the cross-member anyway.

**JeSimmers** · 04-06-2009, 07:02 PM

Very nice, I frequent Rausch Creek...maybe I'll see your work in person!

**Apex** · 04-06-2009, 07:05 PM

Quote:

Originally Posted by JeepinTJ99

You know I was thinking that. Nothing a little grinding action wouldn't correct ... those systems don't really stick out a couple inches farther then the cross-member anyway.

Not even that far, actually I don't think it's even an inch.

A little cutting and you'd be fine, you're right. Here's a pic for reference.

C2U5H · 04-07-2009, 09:51 AM

Quote:

Originally Posted by JeSimmers

Very nice, I frequent Rausch Creek...maybe I'll see your work in person!

You sure will! I'm up there whenever I can get up that way (it's a long haul for me).

Quote:

Originally Posted by Jeep02Apex

Not even that far, actually I don't think it's even an inch ... A little cutting and you'd be fine, you're right.

Thanks for that pic Apex ... it'd be a real quick grinding job to clearance the arms & bushings. Maybe oneday I'll get one ...

And I forgot the most important part of this bumper ... it was free.

Got the 1/8" plate free from the fab shop at work just browsing their scrap pile.

**Bennettj13** · 04-15-2009, 06:18 PM

You directed me here. I want OBA updates!

04-04-2009, 10:51 PM	#5
prd_cdn Web Wheeler Join Date: Apr 2004 Location: !! Posts: 1,049 Profile Gallery Classifieds My Jeeps	VERY COOL Idea and I agree the space above is a huge waste of space.. good use of it!! my plans exactly !!!