Front Bumper re-design - LED lighting, winch mount, DRLs, Road Armor v 2.0 -

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post #1 of 9 Old 01-16-2013, 03:58 PM Thread Starter
Oman Jeep
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Front Bumper re-design - LED lighting, winch mount, DRLs, Road Armor v 2.0

Thought some of you might be interested in the redesign I'm doing on the Road Armor front bumper (Edit: To clarify - for my own personal use, not doing this for the Road Armor company!!) to make it functionally better for the winch mount, and house a few more lights to make it more useful for me in the desert at night, and also raised the side pods for a bit more clearance and to follow the lines of the Highline fenders better.

Original Road Armor bumper

Redesign on CAD

Some of the new parts:

Bending on the press brake:

First cut!

Winch mounted on new plate - much lower and set further back.

Thanks to the SwayLoc - we've freed up the Swaybar mounts on top of the frame so we made the plate longer to set the winch back and tie into those. Made a large oval opening to bring the wires up for the winch etc.

Side pods - water jet cut, press brake bent, gas mig welded. Looking good! The DRL is from the new Mercedes G-Wagen and the same road legal fog lights that Brabus uses.

New centre section - license plate goes in the space intended for the roller fairlead originally (fits beautifully) and then the Synthetic line fairlead comes out underneath. Cut outs for off road LEDs on either side.

Modified Headlight brackets to accept the JW Speaker LED headlights. Marked out and ready to cut away based on the trial and error with the first light. I have smaller versions of the same light (5-3/4") on one of my classic cars and I'm very happy with that. The Xe7 HID lights have served well for the past 7-8 years and although they still work great, I felt like it was time to upgrade again.

Lighting test - all wired up and ready to go in the bumper!

That's 162 forward facing LED lights where there was once only 4 halogen bulbs. It's a significant improvement.

More updates tomorrow night as the bumper gets finished off and the lights get mounted in it. The Jeep Jamboree here is the day after so... it HAS to be done tomorrow!

Hardest part really has been cutting up the original bumper to make use of the parts that we want to keep. In hind-sight, it would have probably been easier to start from scratch and cut out all the parts we need to build a new one. But the original intention was for it to be cut out and assembled like a jigsaw puzzle. Then changed to use the press brake on a lot of it and that made it so much easier.

But hey, for my first bumper build, I'm very happy with how it's coming out

Changes are my designs and CAD work, welding is being done by a buddy of mine. I'm still scared of what I might end up trying to build if I figured out how to weld things by myself

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post #2 of 9 Old 01-17-2013, 10:56 AM
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Looks good. I've always been a fan of your jeep.

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post #3 of 9 Old 01-17-2013, 08:25 PM
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impressive, to say the least
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post #4 of 9 Old 01-18-2013, 01:13 AM
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as always i love following your builds. ready to see this one in action
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post #5 of 9 Old 01-18-2013, 12:17 PM Thread Starter
Oman Jeep
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Thanks guys

Here's some more progress - late last night - getting it together enough to be able to rattle can it and run it on the Jeep Jamboree.

Welds roughly cleaned up. A lot more welding and finishing work planned before powdercoating.

First shot of it on the Jeep with it all plugged in and functional.

Getting the winch installed properly is going to be on the to-do list for after the weekend. We've still got a bit of work to do to make that happen. We mounted the winch body but called it a night after that.

Already very happy with how much lower the winch is now than it used to be up high.

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post #6 of 9 Old 01-18-2013, 12:28 PM
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cool ... unfortuantely this bumper is not on the market anymore ... so your mods from a cool bumper to an even cooler bumper remain exclusive ... LOL

glad to c u around ... still jeepin

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post #7 of 9 Old 01-18-2013, 01:24 PM Thread Starter
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And then here's some pictures from today at the Jeep Jamboree. As mentioned above this is still rough finish, rattle can finish. After some final adjustments we'll be perfecting the finish and getting it powder coated.

Just DRLs

After today's desert drive - we know we do have a bit of rubbing at full compression and steering. We'll be trimming the lower outer edges away before powder coating the thing! Still - not bad at all for my first bumper design
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post #8 of 9 Old 01-18-2013, 05:10 PM
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Looks great! I still perfer my HID's though!
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post #9 of 9 Old 04-22-2013, 03:06 AM Thread Starter
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