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Unread 10-07-2010, 08:47 AM   #1
HHI-Dave
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My bumper fabrication thread...

A little background:

I bought my '00 Wrangler Sahara in early August and immediately joined this forum. As this was my first Jeep, I had a lot to learn (and still do). This TJ is my daily driver but I wanted to make it more off-road capable. I knew that one of the first things I needed to do was to get rid of the silly chrome tube bumpers and fit it with some recovery capable bumpers.

This is how it looked when I first got it:





After spending the last 2 months poring over various bumpers online, I decided to fab my own bumpers. To clarify, I decided to have my good friend and talented mechanic/tuner/welder fab me some bumpers.

We started with 20 feet of 2"x 4"x3/16" steel tubing



























This is how we ended it on day one, shot a coat of primer and bolted it on.

In addition to the six grade 8 bolts, we are going to weld it to the top of the tow hitch which is (obviously) mounted to the frame. This should give it more than enough strength for any recovery. We will also be welding on clevis mounts for D-rings, and fabbing up a spare tire carrier.

Stay tuned for the final product, as well as the front bumper which will be getting underway very soon.

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Unread 10-07-2010, 12:59 PM   #2
HHI-Dave
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Had to add a pic of "Bev" Bev-Tech Inc. Bluffton, SC

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Unread 10-08-2010, 07:49 PM   #3
HHI-Dave
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Got 4 of these ordered today.



BTW, I realize at this point that nobody gives a f*** about my bumpers, but I'm still going to document them for me.
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Unread 10-08-2010, 07:51 PM   #4
jeep0312
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I have been following them actually. They look nice.
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Unread 10-08-2010, 07:53 PM   #5
rickyantanies
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looks good. i wish i could fab my own bumpers. i dont even know anybody that owns a welder. what are your plans for the front bumper?
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Unread 10-08-2010, 07:58 PM   #6
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Quote:
Originally Posted by jeep0312 View Post
I have been following them actually. They look nice.
Thanks for the pity post bro.

Seriously though, I think they're gonna be nice.

Probably going to be a slow process though due to scheduling and work. So far we've got about 4 hours into the back bumper. In addition to the shackles its going to eventually have a tire carrier too.

Quote:
Originally Posted by rickyantanies View Post
looks good. i wish i could fab my own bumpers. i dont even know anybody that owns a welder. what are your plans for the front bumper?
Thanks. I'm planning a stubby front with a small stinger/brush bar and light tabs. I like the looks of the Bulldog bumper



Hope to start on that one soon. I'm fortunate. I've known Bev (pronounced beev) since he was a kid. He built his little import tuning business into one of the most successful shops in town. There's practically nothing he can't do, and they do it all. Its funny to see a minivan getting an oil change next to a lifted monster truck and a supercharged Viper.
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Unread 10-15-2010, 07:26 PM   #7
HHI-Dave
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Got the shackle mounts in the mail today. Hope to get them mounted up soon!

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Unread 10-15-2010, 07:31 PM   #8
NotURMailman
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Looks good, can't wait to see the front.
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Unread 10-15-2010, 08:11 PM   #9
tucanbob
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amazing fab skills, imo.

looking good.
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Unread 10-15-2010, 08:42 PM   #10
cheapjeep06
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How are the mounting bolts held onto the rear bumper? In the pics it appears that they are tack-welded to the bumper from the outside. If not, how did you get them inside the bumper and out the holes? Also, are you going to remove the rear bumper and cut slots the whole way through for the clevis mounts, and then weld them on the front and back surface of the bumper? Just curious as I would like to fab up some bumpers just like yours when I have time at work to do it. Thanks.

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Unread 10-16-2010, 05:36 AM   #11
HHI-Dave
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Quote:
Originally Posted by cheapjeep06 View Post
How are the mounting bolts held onto the rear bumper? In the pics it appears that they are tack-welded to the bumper from the outside. If not, how did you get them inside the bumper and out the holes? Also, are you going to remove the rear bumper and cut slots the whole way through for the clevis mounts, and then weld them on the front and back surface of the bumper? Just curious as I would like to fab up some bumpers just like yours when I have time at work to do it. Thanks.

The grade 8 mounting bolts were installed through the holes from the inside before the ends were sealed up. We used a small hand-held extendable magnet. Then they were tacked into place from the outside.

I realize that welding the clevis mounts front and back is the strongest way, but we are going to cut slots in the front only and weld them. Bev assures me that they will be plenty strong enough to drag the Jeep out when it gets stuck in the local mud bogs.
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Unread 10-24-2010, 02:47 PM   #12
drift2death
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hey bro like the work looks like my rear bumper ( i have a 2" reciever welded in ) i wanna throw on some d-rings its a work in progress n i like that bulldog bumper too
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Unread 10-24-2010, 05:12 PM   #13
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I like how you bent the ends in. Looks good.
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Unread 10-24-2010, 05:19 PM   #14
RogueSpear2023
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Why not add the 2" receiver into the rear bumper, and make you own bumper tie-ins so you can tow with it, because the next problem you are going to have off road is getting hung up on the receiver. Also weld you clevis mounts front and back, it's more work because you have to measure but they will be much stronger, especially since you are talking mud, the suction alone can make your jeep 2x it's own weight.
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Unread 10-25-2010, 07:19 AM   #15
er2ergrn
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Love the way ur bumper is turning out! I have gotten really sick of having anything identical to everyone else's. Thats why I modded my bike and why I am modding my jeep other than the kewl factor!
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