Bumper Build || Next Stage

[JeepinTJ99]

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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:

1. Front bumper build (1/8" plate and 2.25" x 0.120" wall tubing)
2. Two 7" HID off-road lights
3. Twelve circuit aux. fuse box & ground strip
4. OBA system
5. Re-wire entire aux. electrical system (aux. reverse lights, offroad lights, headlights, amplifier, compressor)
6. Rocker guard build (3/16" plate and 2" tubing)
7. Rear bumper & swing-out tire carrier build (2x4x3/16" rectangular tubing, 2x2x3/16" square tubing)
8. Ford 8.8 swap (w/LSD)
9. 3-4" LA lift, TT, SYE, DS
10. 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]

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

[jeff83]

yeah welding cardboard might result in some fire? I think

just kidding real nice start though

[JeepinTJ99]

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]

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

[JeepinTJ99]

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.

[JeepinTJ99]

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]

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.

[JeepinTJ99]

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.

[Jeep02Apex]

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

[JeepinTJ99]

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]

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

[Jeep02Apex]

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.

[JeepinTJ99]

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).

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]

You directed me here. I want OBA updates!