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Unread 11-10-2009, 10:20 AM   #1
Lifted-04-LJ
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2004 LJ Wrangler 
 
Join Date: Feb 2009
Location: Dallas
Posts: 161
Home Built Swing away rear bumper

I know it's been done before but I just had to share...

Total cost has been under $260 and I have steel left over for side steps and a front bumper.

King Metals
2x2x3/16-22ft $50
2x4x3/16-20ft $75

Southwestwheel.com
trailer spindle and 2" u-bolt kit total was ~$45

Home depot
grinding wheels, 3/16x1.5" strap, paint, 1/2" grade-8 bolts, washers, and nuts, safety pin, picture wire, and crimp-on ferrules. ~$50

Harbor Freight
Trailer hitch- $20

Oreilly's
Etching Primer $10

Donated material...
scraps of angle iron (personal stash)
36" of 2x3x3/16 (reinforce rear cross member)

Frame extension 2x4x3/16 - 4"


Fit the brackets


Spindle hinge with bolt flange removed


2" Hole for Spindle.


Brackets mounted and Bolted 1/2" x 3" grade 8 bolts.


Bumper mounted with hinge in place.


__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme

Last edited by Lifted-04-LJ; 11-10-2009 at 10:43 AM..
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Unread 11-10-2009, 10:23 AM   #2
Lifted-04-LJ
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Join Date: Feb 2009
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Posts: 161
More pics...

Second of the hinge in place..


Cap the frame extensions


Cap the bumper ends..


Fit the swing arm..
__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-10-2009, 10:28 AM   #3
Lifted-04-LJ
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Posts: 161
Weld the arm on...


Arm and brackets welded..


On the jeep to measure and place the upright for the spare tire.
__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-10-2009, 10:32 AM   #4
Lifted-04-LJ
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I didn't get pics of the making of the tire mount. I used the stock mount flange and reinforced it with a u-bolt mounting plate the welded it to 2x2x3/16 tubing then bolted it to the 2x2x3/16 vertical from the swing arm using 2" square axle u-bolts. Here is a picture before paint and a close-up after.



__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-10-2009, 10:39 AM   #5
NotURMailman
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Looks good. Are you adding supports to the upright (to make an "A" frame type)?
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I drive on the right side, what's wrong with you?

Quote:
Be very careful with the wife mod. Uninstallation can be extremely expensive. Wife mods have been known to take the Jeep and all other mods during the uninstall process. Also, make sure you service your wife mod properly as often as humanly possible. Wife mods not properly serviced may malfunction or uninstall themselves at any time.
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Unread 11-10-2009, 10:40 AM   #6
FlyinPhil
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looks great! i plan to do one this summer as well
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Unread 11-10-2009, 10:42 AM   #7
Lifted-04-LJ
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Latch assembly..

I used a 1/2" by 1" bolt with a washer and some rebar for a t handle.

I mounted a piece of angle to the bumper. Welded a piece of flat bar to the swing arm. Drilled a hole through the flat and the angle, put the bolt through the hole and welded the nut to the back of the angle iron. I then welded the washer with a notch in it to the bolt and drilled a hole to match the notch in the angle. I then welded a second piece of strap with a washer for a spacer to retain the bolt to the arm. I then welded 2 pieces of rebar to the bolt for a handle.



After Paint
__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-10-2009, 10:45 AM   #8
Lifted-04-LJ
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Quote:
Originally Posted by NotURMailman View Post
Looks good. Are you adding supports to the upright (to make an "A" frame type)?
I added that before the paint. I only added one side ... from the vertical to the hinge at a 30* angle. It got rid of almost all of the flex.
__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-10-2009, 10:48 AM   #9
NotURMailman
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Quote:
Originally Posted by Lifted-04-LJ View Post
I added that before the paint. I only added one side ... from the vertical to the hinge at a 30* angle. It got rid of almost all of the flex.
Right on! I just didn't see it in the pics...
__________________
My RHD TJ - Savvy equipped... And loving it! - Durty Rok Carolina Offroad

I drive on the right side, what's wrong with you?

Quote:
Be very careful with the wife mod. Uninstallation can be extremely expensive. Wife mods have been known to take the Jeep and all other mods during the uninstall process. Also, make sure you service your wife mod properly as often as humanly possible. Wife mods not properly serviced may malfunction or uninstall themselves at any time.
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Unread 11-10-2009, 10:49 AM   #10
Lifted-04-LJ
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Posts: 161
I added the hitch, reinforced the rear crossmember(2x3x3/16") and primed it...




This one shows the swing stop for the arm...
__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-10-2009, 10:49 AM   #11
Lifted-04-LJ
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Quote:
Originally Posted by NotURMailman View Post
Right on! I just didn't see it in the pics...
Sorry about that...
__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-10-2009, 10:54 AM   #12
Lifted-04-LJ
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Join Date: Feb 2009
Location: Dallas
Posts: 161
Here is the finished product.. Rustoleum satin black with self etching primer underneath.



Latch, safety pin, and lanyard.


Reinforced arm


The tire mount again..
__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-19-2009, 02:29 PM   #13
Lifted-04-LJ
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Posts: 161
I had to take off the tire to work on the fron bumper.. it fits in the garage better that way. While it was off I touched up some paint.



the latch assembly..

__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme
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Unread 11-23-2009, 10:40 AM   #14
ritjobbie
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Do you have any pics of the cross-member reinforcement? Does it seem to be holding up okay without frame tie-ins?
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Unread 11-23-2009, 11:15 AM   #15
Lifted-04-LJ
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Quote:
Originally Posted by ritjobbie View Post
Do you have any pics of the cross-member reinforcement? Does it seem to be holding up okay without frame tie-ins?
I added a 2x3x3/16" reinforcement between the 4" frame extensions. The frame extensions are 2x4x3/16" tubing. the bumper is bolted to the frame extensions with 4 - 1/2" grade 8 bolts and 3/16"x2" angle brackets.

The 2x3" tubing was really to tie the hitch to the frame. the welds holding the 2x4" tubing are more than enough to support the bumper and tire carrier. I figured the load of a trailer might be able to flex the bumper. I'm contemplating adding a center mount but to date there are no cracked welds.

pics...




__________________
[URL="http://www.jeepforum.com/forum/f57/marks-81-cherokee-build-1099601/"]81 Cherokee on Tons build[/URL]

2004 LJ, 4.0l, Auto, 35x12.50x15 BFG MT KM2's, 4" superlift, RE SS brake lines, 4.56 Yukons, D44/Detroit Rear, D30 Front, [URL="http://www.jeepforum.com/forum/f9/home-built-swing-away-rear-bumper-898906/"]Custom Tire Carrier Bumper[/URL], [URL="http://www.jeepforum.com/forum/f9/need-help-new-front-bumper-design-build-follow-902984/"]Custom Front Bumper[/URL], Smitty Xrc10, Hi-lift extreme

Last edited by Lifted-04-LJ; 11-23-2009 at 11:23 AM.. Reason: added pics
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