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-   -   Custom Jk Rear bumper (http://www.jeepforum.com/forum/f96/custom-jk-rear-bumper-1493450/)

Dr.Dirty 03-14-2013 03:08 PM

Custom Jk Rear bumper
 
I thought I had already posted this here....


A buddy of mine wanted me to make him a bumper so here is what I came up with.

We started off with some 2x4 to make the frame rail inserts.

https://sphotos-a.xx.fbcdn.net/hphot...11016380_n.jpg

Then cut and notched to fit the supports that will frame out the bumper.

https://sphotos-a.xx.fbcdn.net/hphot...20627981_n.jpg

We started putting our measurements into the computer to see how much we needed to cut and where our bends would be. Then worked up the bumper frame.

https://sphotos-a.xx.fbcdn.net/hphot...72711717_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...11140862_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...26554474_n.jpg

Then it was time to start adding the supports to the upper frame of the bumper, setting it up so we could get a feel for the level. Made sure I could open the rear gate.

https://sphotos-a.xx.fbcdn.net/hphot...99652538_n.jpg

Once satisfied with the top, it was time to measure and weld in the frame rail supports, then put those initial components together.

https://sphotos-a.xx.fbcdn.net/hphot...83153449_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...81551320_n.jpg
https://sphotos-a.xx.fbcdn.net/hphot...16004937_n.jpg

The best thing about that design while building was that we could now set it on the welding table either side up and it sat perfectly.

https://sphotos-a.xx.fbcdn.net/hphot...43015185_n.jpg

We marked the holes while in the frame rails, then drilled them out on the table and welded in the nut for the front bolt.

https://sphotos-b.xx.fbcdn.net/hphot...24345974_n.jpg

Used the same measurement for the lower bar, then angled it upward. A little more cutting and grinding and we had our bottom piece. We added two supports to the bottom to off-center the upper supports, as well as giving us a new place for the license plate.

https://sphotos-a.xx.fbcdn.net/hphot...50291674_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...00789225_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...58215310_n.jpg

Now it was time to place the main tire carrier support and set the spindle in place. The spindle is not only really heavy duty, but is supported by the corners of the two bumper frame bars, its own tube cut to size and welded to the bumper, and a plate cut for the spindle and welded to the spindle tube we made and the bumper itself.

https://sphotos-b.xx.fbcdn.net/hphot...63418258_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...69831754_n.jpg


https://sphotos-b.xx.fbcdn.net/hphot...50442749_n.jpg

https://sphotos-a.xx.fbcdn.net/hphot...61376252_n.jpg

Next came the hoop frame for the tire carrier. We wanted to utilize the bends in the support beam to create a recess where the Kolpin fuel packs would mount, so we angled the hoop slightly toward the Jeep and tacked it on.

https://sphotos-a.xx.fbcdn.net/hphot...39432524_n.jpg

To be continued....

Dr.Dirty 03-14-2013 03:09 PM

https://sphotos-a.xx.fbcdn.net/hphot...97678984_n.jpg
https://sphotos-a.xx.fbcdn.net/hphot...83470553_n.jpg


https://sphotos-a.xx.fbcdn.net/hphot...16240530_n.jpg

We brought the latch around to the side of the main support so it could reach around back and give the best grip to stay closed.

https://sphotos-b.xx.fbcdn.net/hphot...19815281_n.jpg
https://sphotos-a.xx.fbcdn.net/hphot...70401924_n.jpg

Added a tab for the CB antenna, welded a smaller tube to the tire mount plate and slid everything on to test fit.

https://sphotos-b.xx.fbcdn.net/hphot...75294382_n.jpg
https://sphotos-a.xx.fbcdn.net/hphot...35669871_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...04819878_n.jpg

Added some plate onto the top to cover things up nicely. We also put some sheet metal in the lower recesses...

https://sphotos-a.xx.fbcdn.net/hphot...07090038_n.jpg


https://sphotos-b.xx.fbcdn.net/hphot...39029811_n.jpg
https://sphotos-a.xx.fbcdn.net/hphot...76897432_n.jpg
https://sphotos-a.xx.fbcdn.net/hphot...97145801_n.jpg

Some final fitting shots before bolting it to the frame and putting everything on.

https://sphotos-b.xx.fbcdn.net/hphot...09895928_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot..._9816763_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...28178402_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...01878640_n.jpg
https://sphotos-a.xx.fbcdn.net/hphot...80744869_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...23900732_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...54315989_n.jpg
https://sphotos-b.xx.fbcdn.net/hphot...09020285_n.jpg

DAYJ 03-14-2013 06:54 PM

Pure awesomeness.... Great skills, I'd buy it!

1222 03-14-2013 09:34 PM

Very nice, is that the first time you’ve used that design?
:cheers2:

zenman 03-15-2013 10:30 AM

I can just hear my brakes squeeling and that big tire getting bigger in my whindshield, lol!:laugh:

awinski 03-15-2013 11:42 AM

looks sweet, i like the latch. ive been trying to find some similar with no luck!

Metalman 03-15-2013 12:26 PM

Quote:

Originally Posted by awinski (Post 15139304)
looks sweet, i like the latch. ive been trying to find some similar with no luck!

Look no further :cheers2:

http://www.emsoffroad.com/store/inde...roducts_id=449

edit:

or

http://www.reidsupply.com/sku/TC-344-R/ (lockable)

awinski 03-15-2013 02:41 PM

thank you!

Dr.Dirty 03-15-2013 08:25 PM

Quote:

Originally Posted by 1222 (Post 15137039)
Very nice, is that the first time you’ve used that design?
:cheers2:

Yeah its was a build as we go the way he wanted it.

Quote:

Originally Posted by Metalman (Post 15139528)

Not a huge fan of that latch because it doesnt lock.

This is the latch I used

http://www.reidsupply.com/sku/TC-344-R/

Metalman 03-19-2013 11:29 AM

^^ Oh hell, my bad I didn't know that. That's a great looking bumper, excellent work! :cheers2:

Dr.Dirty 03-26-2013 03:08 PM

Quote:

Originally Posted by Metalman (Post 15158319)
^^ Oh hell, my bad I didn't know that. That's a great looking bumper, excellent work! :cheers2:

thank you sir!:cheers2:

awinski 03-26-2013 03:31 PM

thanks for the latch help. ill be hopefully using one with my rear stinger!

Dr.Dirty 03-27-2013 06:46 AM

Quote:

Originally Posted by awinski (Post 15198366)
thanks for the latch help. ill be hopefully using one with my rear stinger!


Reid sells a ton of different ones to in case you need something else

jehnmg 03-27-2013 08:28 PM

Excellent custom build. Well done!
Just curious, how much does it weigh?

Kenny-g 03-28-2013 11:01 AM

Damn that's an awesome one off bumper/tire carrier. Very heavy duty and sturdy looking. I love it! Nice job. Makes me want to learn how to weld and get practicing, that's for damn sure lol


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