XJ rear bumper fab!!!!

[highlander]

OK I'm going to build a bumper like this.


http://www.naxja.org/forum/showthread.php?t=93051&highlight=rear+bumper+point


Looking at a few mods to it to accept a tire carrier and a few goodies.


Anyone interested in something similar???
Looking to split the costs of the metal with someone if you would like!!!

DISCUSS!!!! :thumb:

[gtrsnax]

Funny, I was just telling Kyle today...... "We should start looking into buying some 2x4 to make bumpers with"

So, Im on board anyway.......

Kyle?

[vabchxj]

I'd split the costs, just name the price.

I'd extend the bumper to make the tire carrier. I'd fabricate the receiver on the bumper. And I'd fabricate the mount for d-rings. Sounds good? I'm not much of a fabricator but I am about to get a program called AutoCAD to design homes (I'm an architect). But I can still design the bumper in the program or we'll just have to hand sketch it.

[hecull]

Wynn, I'm in!
I've got the tools to cut and weld the steel. Let's do it!
Kyle

[vabchxj]

I wish anyone can possibilty teach me how to fabricate and weld. It'd be a great experience.

[K9]

I wish anyone can possibilty teach me how to fabricate and weld..

No open sneakers and NO SHORTS, especially with ARC welder. :bang:

http://i65.photobucket.com/albums/h237/TsiTalons_photos/Bumper%20Pics/WeldingBumperSupports.jpg

[green73]

Did I see stacked plates welded together for the D-ring tabs? If so that's the only thing I would change. It looks nice, functional, and best of all easy/cheap to mimic. Go for it guys, and post up pix!

[gtrsnax]

I measured that I'll only need about 9 ft TOPS out of the bundle. Less than 4 for the front, a little more than 4 for the rear. A little extra just in case hehehe

[akxj]

i hope you have intentions of tying your bumper to the frame underneath...if you don't you might as well throw it in the trash...va beach xj, stop by the house when you get a chance and you can take a look at mine up close and get a few idea...

[highlander]

Yea we are tying the bumper to the nutserts under the frame. I had also planned on buying the d ring pieces from ruffstuff.


Definately going to extend it and add a tire carrier!!!!!

[gtrsnax]

Do the D-ring mounts go all the way through? Or are they surface welded?
When Eddie built DJ's bumper, his mounts went all the way through to the back of the bumper too. I've seen that before on other builds and I really like that idea.
I plan on tying into the nutserts too since I may retain the recovery hooks anyway.

[highlander]

looking at using these

http://www.nates4x4.com/catalog/product_info.php?cPath=28&products_id=39

and one if these!!!

http://www.nates4x4.com/catalog/product_info.php?cPath=28&products_id=40

[DJEEPER]

i dont know what eddie is up to these days, but i know he used to sell them all the time on ebay (D ring tabs and such..)

maybe help each other out eh?

[gtrsnax]

looking at using these

http://www.nates4x4.com/catalog/product_info.php?cPath=28&products_id=39

"Perfect for thru-welding in 2" rectangular tube" Perfect!

I'd prefer to buy from Eddie if he's still making them though, support the locals ya know......

[BESRK]

I still have some 3/4"x2" stock. I usually cut them 4.5" long to work with 2" thick bumpers but I can cut 'em longer if needed. I also drill the hole out to 1" so you can use a 7/8" shackle (although the 3/4" shackle is rated at 6.5 tons and is plenty). I do them on eBay for $19.99 a pair plus shipping. Around here I'll do them for $15 a pair.. I can try to get some done between now and Saturday as I might be going TDY for 2 weeks starting on Sunday (not sure yet). If anybody wants them, just let me know during the next 2 days or it'll have to wait till I get back.. :wave:

[gtrsnax]

My vote? -- No hurry Eddie. Thanx

[AlxJ64]

GRRR.. I wish I could get my hands on the pics from where I fabbed my Spare Carrier....

I just re-used my stock carrier plate. I chopped it off with a chop saw and added some plate to the back for Reinforcing. Worked out decent.

Fabricating is not that hard to do... Granted it is more of an art blended with Engineering. It comes with experience, so the more you do, the better you get at it.

[hecull]

Eddie, I'm in for two pair of your shackle mounts, 3/4" hole will work for me. I just don't have the tools to work with that size stock. No hurry as bumper fab is a quite a few weeks down on the list. Post up when you get back from TDY. If you have spare time on your hands before you leave, that works too.
Thanks!
Kyle

[goXJ]

count me in for a rear bumper, and two of the shackle tabs! :thumb: might just get steel to make sliders at the same time. has anyone started checking on sources for steel?

[AlxJ64]

BMG Metals in Chesapeake... Consider it P town cause its off of Victory Blvd is decent... And I get alot of my Stuff from onlinemetalsinc Because they don't charge any cut fees. But, you have to pay shipping.

[highlander]

Still on, getting prices for steel. Everyone still in???


I can have it delivered to my shop for a minimal charge from Richman Steel.

[gtrsnax]

In !

[Rockjock]

Damn you guys need to shut-up and build! :flip: I think you XJ guys have been planning bumper builds for over a year. Just build it or buy but get over it. :flip:

Cheers,
Kevin :cheers:

[danielj903]

:up:

[XTrmXJ]

Ill get in on this but I want to do my own design with the same material, heres what Im looking at doing, might take a little longer...







http://www.photodump.com/direct/davephillips/rearbumperjosh.jpg
http://www.photodump.com/direct/davephillips/rearbumperon748.jpg

[IH8RDS]

Jon, Your on the right path. That design is the one I like.

[XTrmXJ]

Its a similar design to Wyns but skinned with plate to slide or have a skid effect, still same amount of material and some extra plate..

Wyn I hope youve added me into this on metal

[gtrsnax]

Any progress Wyn? Need any help? Prices? Colors? Fabric?

[K9]

Everybody is in such a hurry to get it in the rear

[hecull]

Okay, I've now got one of these to cut things:

http://www.harborfreight.com/cpi/photos/93700-93799/93762.gif

And I've CAD'ed out a design, though I haven't worked out the mounts yet:

http://www.kyleodom.net/pictures/4x4/bumper.jpg

Wynn, any word on steel prices? Let's do this!
Kyle

[akxj]

those bandsaws don't cut worth a shit...i took mine back the day after i got it and got a milwaukee portabandsaw....

[hecull]

Eric, did you replace the blade on it? The blade it comes with is NOT a bi-metal blade and is worthless. With a "real" blade, it's zippy!
KO

[akxj]

cool...i might buy another one...

[IH8RDS]

Here is a excellent build Steve from Australia is doing

http://www.naxja.org/forum/showthread.php?t=899237

Here is a teaser

http://www.4wdlinks.com.au/albums/Rear-Bar-and-Carrier/Bumper_040.jpg

[highlander]

Got the pricing down!!!!!! :cheers:


Total cost for metal for 1 bumper is 89.75!!!! (without pull hitch and d-ring shackles)

I got a set of the D-ring tabs from Eddie and highly reccomend them!!! :thumb:


Send me a PM if you are in!!!!


This price is for 4 bumpers... May be more or less depending on the order!

[green73]

Are you planning on bending up the sides like in the pic above, or just going flat? If you are planning on the bends, how, a brake or other?

either way this all looks interesting.

[XTrmXJ]

Like I said im still in, but I will be changing my plans for my bumper using the same amout of metal, If I need extra, I will go ahead and just buy more but I shouldnt need any extra, If anything Ill just hit Eddy up for scrap

[highlander]

ok.. Got 3 people. Anyone else????

[gtrsnax]

ok.. Got 3 people. Anyone else????

Are Kyle and I two of those people?

[Misfit8]

Any idea on total weight..........

[highlander]

your in Tom???

We can make you a bumper for the TJ... :thumb:

[gtrsnax]

Yes, in like Laura Flynn

[K9]

Are you planning on bending up the sides like in the pic above, or just going flat? If you are planning on the bends, how, a brake or other?
Harbor freight has a 36" brake on sale, will do 12ga.. They are on sale for less than $179 I think

[IH8RDS]

In the picture above he scored the metal, bent manually and then welded at the bend.

[highlander]

OK

Order being picked up


Friday January 19th.

Whoever is in we will need all monies by then!!!


Fab day on the 20th???? :paddle:

[BESRK]

I can do other stuff besides clevis mounts now.. :D


http://memimage.cardomain.net/member_images/3/web/543000-543999/543576_583_full.jpg
http://memimage.cardomain.net/member_images/3/web/543000-543999/543576_582_full.jpg
http://memimage.cardomain.net/member_images/3/web/543000-543999/543576_584_full.jpg
http://memimage.cardomain.net/member_images/3/web/543000-543999/543576_581_full.jpg

[gtrsnax]

Looks like someones got a lathe up and running hehe.
Probably too late for me to ask, but what exactly did I commit to? Don't we have like 3 "I need metal" threads floating around?
Is it 2x5x3/16 or something ? Is it too late to get enough for a front piece too? I figgered I need 9' total for front/rear on my heep.

[IH8RDS]

That looks incredable Eddie. Good work :thumb:

How much grease does it take to fill it up?

[BESRK]

That looks incredable Eddie. Good work :thumb:

How much grease does it take to fill it up?

Ummm... 22.5 pumps on a big grease gun. Twice that amount on a little grease gun... and 13 seconds on an air grease gun.. :mrgreen:

Honestly though, the zerks are kind of a waste. If you pack the bearings with a quality synthetic grease, they should outlast the vehicle. It's not like they're spinning at 5,000 rpm. They only see a half rotation a few times a week.

[IH8RDS]

That looks incredable Eddie. Good work :thumb:

How much grease does it take to fill it up?

Ummm... 22.5 pumps on a big grease gun. Twice that amount on a little grease gun... and 13 seconds on an air grease gun.. :mrgreen:

Honestly though, the zerks are kind of a waste. If you pack the bearings with a quality synthetic grease, they should outlast the vehicle. It's not like they're spinning at 5,000 rpm. They only see a half rotation a few times a week.

Ha HA 22.5 pumps. That's about half a tube :mrgreen:

Well it will be good to expel the water that might migrate in there.

[AlxJ64]

Yea.. and you can market it as a "High Performance" hinge. and thus sell it for twice as much! :thumb:

[highlander]

IS that why I couldn't find spindles at Northern the other day???? *L*

[XTrmXJ]

Wyn, get up with me and I will give you the money, I will be in Vegas on the 17th so when you get the metal either you can hold on to it till I get back on the 10th of Feb or you can drop it off at my house

[BESRK]

IS that why I couldn't find spindles at Northern the other day???? *L*

I order my spindles from the internet.. I get 'em for like $7.60 apiece and free shipping if I get like $150 worth of stuff....

[highlander]

what are those rated for eddie???

[BESRK]

1000lbs.. The trick is to latch the tire swing so that the latch shares the load with the spindle.
http://memimage.cardomain.net/member_images/3/web/543000-543999/543576_213_full.jpg
http://memimage.cardomain.net/member_images/3/web/543000-543999/543576_214_full.jpg
http://memimage.cardomain.net/member_images/3/web/543000-543999/543576_234_full.jpg

[akxj]

where do you pick up your spindles at???

[gtrsnax]

I order my spindles from the internet.. I get 'em for like $7.60 apiece and free shipping if I get like $150 worth of stuff....

But I guess you want the website huh?

[BESRK]

How can I make any money off you guys if I give away all my trade secrets? :mrgreen:

http://www.etrailer.com/mm5/merchant.mvc?Screen=PROD&Store_Code=E&Product_Code=R104BT8&Category_Code=

Northern for the bearing kits $9.XX

www.smallparts.com for De Sta Co Latches (2000lb safety latch type) $30.XX

www.mcmastercarr.com for pretty much all other small things..

www.weldingsupply.com for .035" solid wire $17.XX per 10lb roll

[gtrsnax]

How can I make any money off you guys if I give away all my trade secrets? :mrgreen:

I'll pay for a stinger once I build my front bumper :D

[K9]

I have a set here I need to get rid of too, 4.5" long, exact same cuts.

I don't have a vehicle that can use them.

They came from here http://www.rokmen.com/products/diy_fabrication_parts/diy_fabrication_parts.html

[akxj]

How can I make any money off you guys if I give away all my trade secrets? :mrgreen:

http://www.etrailer.com/mm5/merchant.mvc?Screen=PROD&Store_Code=E&Product_Code=R104BT8&Category_Code=

Northern for the bearing kits $9.XX

www.smallparts.com for De Sta Co Latches (2000lb safety latch type) $30.XX

www.mcmastercarr.com for pretty much all other small things..

www.weldingsupply.com for .035" solid wire $17.XX per 10lb roll

how bout this eddie....i'll get the southside and you get the northside....deal?? :rtfm: :rtfm: :mrgreen:

[BESRK]

How can I make any money off you guys if I give away all my trade secrets? :mrgreen:

http://www.etrailer.com/mm5/merchant.mvc?Screen=PROD&Store_Code=E&Product_Code=R104BT8&Category_Code=

Northern for the bearing kits $9.XX

www.smallparts.com for De Sta Co Latches (2000lb safety latch type) $30.XX

www.mcmastercarr.com for pretty much all other small things..

www.weldingsupply.com for .035" solid wire $17.XX per 10lb roll

how bout this eddie....i'll get the southside and you get the northside....deal?? :rtfm: :rtfm: :mrgreen:

Hehe.. actually, I'm no threat to any local fab shops. I sell the small trinket here and there but make most of my bigger sales on the internet. I do better dealing with people I don't know. When I'm face to face with someone I know, I tend to undercut myself bad and barely make back my cost on the item..

[akxj]

i used to be the same way, then i figured i better quit screwing myself...do sell most of your stuff on ebay??? or just different forums...

[hecull]

I have a set here I need to get rid of too, 4.5" long, exact same cuts.
I'm interested. Price?
Kyle

[BESRK]

i used to be the same way, then i figured i better quit screwing myself...do sell most of your stuff on ebay??? or just different forums...

Sell quite a bit on eBay (over 400 feedbacks so far) and guys from Jeepforum. Being the Fabrication Forum Moderator gets me emails/PMs all the time from people looking for bumpers, stingers and other stuff. I really should stop fawking around and open up a small shop somewhere... someday :roll:

[akxj]

no shit huh....i've been toying w/ the idea of doing some ebay stuff...who do you use for shipping out of curiosity...wish you were closer we could go in on a small shop together....

[BESRK]

I ship with Fedex.. cheaper than UPS. Just print out the label.. slap it on the box or whatever, drop it on the counter and walk out. They're awesome. I once shipped two boxes out. Only I mixed up the labels and sent the wrong items to the wrong customers. I called Fedex and they caught the shipments midstream and rerouted them for me..

[hecull]

:hijacked:
I have to second Eddie's post. Once you get an account with FedEx, they really cater to you. Not to mention, again, it's cheaper.
Sorry Greg.
KO

[IH8RDS]

yea but they only insure up to $30,000 :(

Kinda hard to ship $360,000.00 parts. :mrgreen:

[AlxJ64]

I've always had better luck with UPS personally, but then again I've still got my parents account open from when we had the John Deere Dealership, so we get stupid good rates. However, I do own a few stock shares in BOTH Fedex and UPS... Needless to say, the Gas prices really fucked up my share prices.. :bang:

[highlander]

Everyone still on for this weekend???? :twisted:

[XTrmXJ]

Wyn I need to get up with you before this weekend, other wise you will have to wait until mid Feb

[hecull]

Everyone still on for this weekend???? :twisted:
Where and when?
KO

[akxj]

holy shit....you guys might actually build these things...

[IH8RDS]

holy shit....you guys might actually build these things...


:up: your too cruel :mrgreen:

[XTrmXJ]

Ive just been waiting on the deal for the steel, Ive been chopping other things up

[highlander]

DING!!!!!

metal ordered.... should be here friday!!!!!!


I have for the bumpers....

me
jon
kyle
tom
rob

Gentlemen start your welders!!!!!!!!

[XTrmXJ]

Gentlemen start your welders!!!!!!!!

SHIT BITCH, Ive been using my welder for the past week

[XTrmXJ]

Ill bring my XJ over also for a mock up, I should be able to roll mine into the shop

[gtrsnax]

Gentlemen start your welders!!!!!!!!

The damn thing ran all weekend at my house hehehee. Went through a spool of wire and the tank is in the "gonna needa refill" area. Tims tire carrier took the brunt of all that extra weight.

[AlxJ64]

I have a set here I need to get rid of too, 4.5" long, exact same cuts.

I don't have a vehicle that can use them.

They came from here http://www.rokmen.com/products/diy_fabrication_parts/diy_fabrication_parts.html

You wouldn't happen to still have those or did Kyle snag em already?

Anyone else got any? How much?

[hecull]

I understand it's not seperated.
We can meet at Tom's on Saturday morning to hack it up as needed.
All my tools, saws, welder, etc are there.
I also owe you some money.
Let me know how you want this to go down.
Kyle

[highlander]

Well...

Friday night I was hoping to hack the peices at my shop. (easier to transport)

Saturday morn weld till you drop(or have to go to work)


but..... it looks like I may have to work tomorrow night.....

[highlander]

CHopsaws will be needed!!!!


I might solicit Jon and James for a saw but do you have one Kyle???

[gtrsnax]

Wyn...........

If you're doing onsite cutting.........

For my piece of the 2x5, I need a cut

42" long, then leave the other half as is.

104
-42 (front bumper measurement)
--------
62" is the other half, thats fine. My factory bumper is 50"

[AlxJ64]

I used a 60" piece for my rear bumper.. Sounds like you'll have enough left over to do one of those too. :cool:

[hecull]

do you have one Kyle???
I have a small 7" chop saw for small tubing and angle iron. Everything else gets cut with the band saw which is at Tom's and not easily moved. If it would help, I'd bring my small chop saw. It's not going to be enough for the main 2x5 tube though.
Where are we meeting, and when on Saturday?
Kyle

[XTrmXJ]

Id say whereever there is room and where the tools are, James has a 14 inch chop saw that we can use but I dont know if it will work, Ill will have to take a measurment when I get home.. I vote for Wyn's shop because there is a lot of room and Im sure the metal is in 20+ ft stock.. In case of, we can use my truck and trailer for what ever reason to move tools or metal

[BESRK]

How are you guys cutting the holes for receivers and clevis mounts? If you get the bumper blanks cut to length and mark them where you want the holes, I can plasma the holes for you guys. Would probably take me less than an hour to do all of them. I just got my new Plasma Cutter so it would break it in. I just can't really do any work outside right now.. City Code guys are breakin my balls. Soooo.. I'm stuck in the garage doing my own bumper projects among other things.. just let me know.

[ROBBS94XJ]

I need directions to wherever we will be. PM me if you need to

[XTrmXJ]

Eddie, Ill be buying one of your swivel mounts, Ill get back to you on it when I get to that point

So where are we doing this, I wont beable to show up until after 9pm tonight, so more in likley Ill work on the stuff tomorrow uless you guys will be working well after 9

[highlander]

Metal is here

Everyone call me!!!!(involved with this project :flip: )


715-2292

[IH8RDS]

Please post up pictures of your progress :cool:

[XTrmXJ]

Please post up pictures of your progress :cool:

I like to weld naked, Ill take pics especially for you Scott

[IH8RDS]

Jon, show me something I havent seen :mrgreen:

[hecull]

How are you guys cutting the holes for receivers and clevis mounts?
I was going to torch mine, but if you're offering the plasma, I'm accepting!
Kyle

[gtrsnax]

How are you guys cutting the holes for receivers and clevis mounts?


Dremel?





























:mrgreen: :up:

[BESRK]

Yeah.. just bring the bumpers by sometime after about 12 noon. That's when I get back from the Coffee Run. Should take just a few minutes. I already played with the plasma cutter. Thing cuts thru 3/8" plate faster than my old one cut thru 3/16"... I can also cut the tapered ends if you guys want.. whatever. Only takes me a few minutes per bumper..

[akxj]

so wheres the pics at....didn't you guys get anything done today....i started building a the HD TJ bumper w/ tire carrier...

[hecull]

No Pix
We had... Issues...
Basically today was cutting up 24' sticks into what we needed, and with as simple as that sounds, it wasn't. Cutting got ugly with a busted up band saw, broken blade, replacement put in backwards... etc... Although this was an independent DSO fab project, there was plenty of Buzzard Luck around.
When I left at 2:30, everyone had their main tube cut, "rear crossmember" mount cut and drilled, and stand off cut.
Wyn had a full mock-up of the rear part of his done, the mounts were all together, but the main tube wasn't finished, and the sides weren't even started.
Jon and Rob went to Jon's to work some more, Wyn went to work, and I gave up for the day.
The good part about all this is I think everyone now knows what design they're going to make.

[BESRK]

Offer still stands to plasma any holes you guys need...

[highlander]

Eddie

I'm going to take up your offer, just may be one day this week after 4 pm.


Also need another set of d-ring mounts and another spindle peice!!!


Thanks for the assist!!! :thumb:

[XTrmXJ]

Well Rob and I worked on building his Bumper and we used my XJ for the moc up since it was in front of the garage (blocked in by trailer).. We basically have his complete except for the diamond plate skinning on top(I have excess amout laying around).. we decided to try and match the body design so now the bumper has a curve to match and is ready for bolt on.. I have all the peices to make mine but we've been working on Robs and had to consume several amounts of beverages to complete.. I now have an extra XJ in the drive since Robs a pussy and had to have his wife come pick him up... HAAHHAHAHA (KUDO'S ROB on that call) Dam its taken me a while to consintrate to write this

[BESRK]

Eddie

I'm going to take up your offer, just may be one day this week after 4 pm.


Also need another set of d-ring mounts and another spindle peice!!!


Thanks for the assist!!! :thumb:

I may be working a little later than normal because I'm running the rifle range all week.. but if I'm home, I'll do it.

[XTrmXJ]

Eddie, im not going to be needing the spindal like I previosly mentioned, Ive gone a different route, But what Wyn is talking about is for Rob and himself

[ROBBS94XJ]

I appreciate the work Jon!!! And it's A good thing I called the MRS. cause there was an accident right down the road from your house and there eleventy billion cops out there. All I know is I'm dog-ass tired and I have some nasty black slimey boogers in my nose, so I'm going to bed.

Later ROb

[BESRK]

I have some nasty black slimey boogers in my nose


Grinding boogers.. those are the best kind. I save 'em for dessert.

[ROBBS94XJ]

What's everyone's progress on this?? Wyn did get the holes plasma'd yet?

Jon, unfortunately I have to work tomorrow. You think I might be able to swing by after work on Friday and get a few things done. If not I'll just wait til' you get back from Vegas, I'm in no hurry.

[gtrsnax]

What's everyone's progress on this??

Nothing so far. I have two pieces of 2x5 leaning against the wall in my garage. Right now they're just decorations.

[XTrmXJ]

What's everyone's progress on this?? Wyn did get the holes plasma'd yet?

Jon, unfortunately I have to work tomorrow. You think I might be able to swing by after work on Friday and get a few things done. If not I'll just wait til' you get back from Vegas, I'm in no hurry.

Ya just roll over after work and we'll work on it, I have tomorrow off, Im accualy rolling out of work around 1800 or so

[akxj]

jesus, i've built 5 bumpers since page 3 of this thread...worse than a bunch of school girls...and even eddie's offering to help...look i built this in 2 days (8-10 hours total work)

http://i41.photobucket.com/albums/e287/akxj/DSCF0926.jpg

and i took my time pissing around w/ it too...get to work yah bunch of slack asses...wow, that's kinda how i sounded in the military w/ my young troops...hahaha... :razz: :razz:

[XTrmXJ]

I work, and Im having to work out side since the garage is full, and Jon no like to worky outside in the cold

[gtrsnax]

Im not exactly sitting around with my thumb up my butt either

[akxj]

I work, and Im having to work out side since the garage is full, and Jon no like to worky outside in the cold

coming from a guy who wears a PJ emblem on his hat; i figured you would be more hardcore than that...and Tom sounds like you're suggesting that i sit around with my thumb in my butt...just some friendly ribbing boys...if yah need help i'm always here...

[gtrsnax]

Nah, I wasnt suggesting you sit around either, I mean shit, you got a crap load of bumpers built recently. I was just saying I've had too many other things going on. Bumpers are kinda far down on my list at this point.
It's all good

[goXJ]

tom, don't let me find out you put midget porn ( :ts: ) ahead of fabbing and wrenching, again.

might be time for another intervention. :mrgreen: :stick:

[gtrsnax]

Hey, if she's got an Australian accent, it's more important than wrenching!

[akxj]

Hey, if she's got an Australian accent, it's more important than wrenching!

agreed....ps...i do sit on my ass alot...

[hecull]

jesus, i've built 5 bumpers since page 3 of this thread
we're not getting paid to make them though, so we can take our own sweet time :cheers:

[Misfit8]

I bought mine in less than a minute..........

[IH8RDS]

I bought mine in less than a minute..........

what one did you get?

[AlxJ64]

Heres a CAD Drawing of mine plus the reciever and D-Rings... I got bored today at work. It doesn't have to attachment brackets either. But I'm getting ready to build this one again for an XJ, cept I'm moving the Hinge down below the top of the bumper so that the Gate is Garunteed to clear it..

[akxj]

well hell we're making progress i'm seeing pictures of them.... :cheers: :flip: nice CAD drawings...

[Joe98XJ]

Nice design! I really like the functionality and hell I'd love to have one, are you selling them? And if so what's your price? :cheers:

[AlxJ64]

I've considered selling them,

Lemme get this one done for this other guy's XJ and based on the price of Materials and the time that goes into it I'll throw a price up for em if I feel energetic and build a few more. I know that I can build and sell the ones for the TJs for about 450-500$. It depends on whether there's a Reciever Hitch and D-ring Tabs in it or not. I need to pick up that set from Eddie. I've just been super super busy.

But also theres a few other guys on here that Fab for money that may also be able to help you considering how busy I am these days. You might consider checking them out too if you want.

[gtrsnax]

www.erokfab.com

[minydigger]

You said you are going to move the tire carrier to the outside of the bumper? Can you put up the cad with that design in it? I'm looking to ad a carrier to my ZJ bumper that I just built but can't put it on top like the one pictured above. I need some Ideas, my d-rings are in the way so it needs to bend up around them.

[AlxJ64]

yea, I'll throw that design up Saturday since its all on my Office Computer and I'm off till Saturday.

How far down the bumper are your D-Ring Tabs? And do you Have a Reciever hitch like the one above? Or is it lower and not integrated into the Bumper?

[minydigger]

No Reciever hitch not yet at least. My d-rings are probably 2" down or so. You think 2" square tubing is enough to hold a 35" or 36" tire.

[AlxJ64]

Ohh yea. Thats what I'm using on mine and so far so good. The only problem I've had with mine so far is I get a little flex out of some Local Web Yielding that occurs.

I'll throw the CAD up with some section cuts to show ya how it works.

Updated:

Here is MY design for the swing out Carrier with using an external style hinge mounted off the bumper. This also allows for the bumper to still be underneath the lift gate like the stock XJ bumpers are.

I'm sure it needs tweaking to particular designs, and maybe some more/less or repositioned gussets on the swing, but overall I feel like it should work pretty damn well..

BTW this design is free for use with-in the DSO4x4.com, but PLEASE, don't let me see these things on Ebay unless I give a go ahead to use the design.

Thanks and lemme know what ya think!

[ROBBS94XJ]

Missed the coffee run this morning, but got my bumper test fit. It's not real fancy but will be functional when done and will have a somewhat stock appearance. I've decided to keep my stock hitch for now. Still need to cut the ends to fit body lines and get pieces for tire carrier from Wyn. I'm going to try (if the baby doesn't decide to come) and make it to your place this weekend Jon so I can to finish it up and give you some help where you need it.

[hecull]

You are getting there!
What the pictures don't show, and something I'm really impressed with, is that the bumper curves with the body line of the hatch. Nice touch!
Kyle

[minydigger]

This is the one I am working on for my ZJ not done yet but its getting there, the piece of 3x5 I had was bent so I wasn't able to go all the way a cross the back like you did with yours. Looks good thou.

[outlawjeep]

I really like that ZJ one. It turned out nice. Are you going to add a swing out to or just leave it like it is?



Ray

[minydigger]

Its going to either swing out or or swing down not sure yet.

[Misfit8]

http://www.naxja.org/forum/showthread.php?t=907275

[ROBBS94XJ]

I don't plan on using mine as a recovery point so hopefully that will help to keep it from cracking the mount holes and for extra support there is a piece of flat stock welded on the mount that extends into the frame rails and bolted in using the same nut plates that hold the factory hitch on.

[XTrmXJ]

After looking at the others I noticed they didnt have the internal brace like we do, second on mine (just built it) I also have more bracing added on the outside to further help out.. I also dont plan on putting a spare tire rack on either

[XTrmXJ]

By the way, Mine is done now, just needs paint.. I went the barbarak way and didnt do anything special like what I did with Robs, I figure I really didnt care about looks since its been taken off the road, I was looking for raw protection untill I can get around to buggifing the back

[ROBBS94XJ]

Damn that was quick...pics? I'll be coming over this weekend hopefully to get mine finished up. On another note I spent the better part of this morning in urgent care to find out why my eye was bothering me all last night. Had a sand sized piece of metal stuck in the colored part. Must have got hit with a spark from the grinder. I even had my safety glasses on too, except they didn't do me any good being on top of my head. Oh well, I won't forget to put them down next time right?

[XTrmXJ]

Ya It only took me a few hours of welding, I would have been done sooner if I hadnt had to run and get more wire for the welder and have to get other parts to install my winch.. I just need to paint and weld some Dring holders..

[K9]

10 page thread now? Are these fucking things built yet? :flip:

[Misfit8]

What do you think.............

[XTrmXJ]

I built mine yesterday

[hecull]

Update...

I finally got the chance to work on this. It's still a work in progress.

I have the factory gas tank skid and rear tow hooks. As such, I should have expected having the nut strip in place. However, because I'm dumb, I didn't. So, I had to deal with this:
http://buzzardluckfab.com/images/kdo/dealing_with.jpg

I had planned on doing the frame tie in inside the frame, now that I know I have what I do, I'll do it outside.

http://buzzardluckfab.com/images/kdo/parts.jpg

I grinded out the hole, and it took a while on the 3/8" steel. I also beveled the edges of the 2 by 3" 3/16" stand-off tube. I'm now ready to line things up to tack in place.




http://buzzardluckfab.com/images/kdo/fitment.jpg
The problem here is the XJ is pretty well up there and on a slant, and I'm working alone. Call me a Redneck, but I got it done.

http://buzzardluckfab.com/images/kdo/done.jpg
Got all measurements spot on, tacked the thing into place. Took it off and welded it. When I mounted it back after welding, I'm a total of 1/32" off in any direction. I'll take it for the conditions!

It's ugly, I know, but this is only step one. By next week I hope to have something better to show. The XJ still earns it's BLF sticker :)

BTW, Wyn, got any more of that 2x3x3/16"? And/or the 2"x3/16" plate?
KO

[maduece]

Looking good Kyle, I had a good laugh when I saw that pot Tom pulled from the swamp being used as a jack stand extension. Shoulda known that was going to be dragged into something.

[akxj]

looks good man...BLF has come along way you guys are impressing the shit out of me...especially tim and his cage stuff....

[ROBBS94XJ]

Finally got mine painted up and somewhat finished. Still need to figure out the best way to mount a swing away tire carrier. Any suggestions?

[hecull]

I finally got back around to working on this.

I put the receiver in last weekend, this weekend I was going to gusset up everything and bevel the outsides. Still a lot more I want to do, but here's an update. Please excuse the cell-phone pics. I managed to leave my camera at home again.

First had to make some gussets. I made a ton, both in 2" and 2.5". I made more than I needed, while I was cutting I might as well make some to have around.
http://buzzardluckfab.com/images/kdo/gussets.jpg


I tried to use a portable bandsaw to bevel the ends of the bumper. That wasn't going so hot. Ended up just using a cutoff wheel on the grinder.
Cutting and welding the caps was a no brainer. Grinding everything to look nice was a pain, and I'm going to be smelling steel for weeks. But, I think it turned out well.
http://buzzardluckfab.com/images/kdo/bumper1.jpg
http://buzzardluckfab.com/images/kdo/bumper2.jpg
http://buzzardluckfab.com/images/kdo/bumper3.jpg

I've got some shackle mounts that I was going to add, but I'm not so sure I want to do those now, as it looks really clean and simple how it is. That leaves the receiver as a tow point, but I have the factory tow hook in the back in case.

Next up... Cut the quarter panels down and extend the sides of the bumper to the wheel well.
Kyle

[gtrsnax]

Looks nice!! I like the angle on the ends. It's smaller than what I thought you were going for, even despite what we talked about earlier today.

[CPike3]

Looks real good. The cuts on the sides make it look much better. What did you paint it with? It looks textured.

[hecull]

Looks nice!! I like the angle on the ends. It's smaller than what I thought you were going for, even despite what we talked about earlier today.
TY! Once I started drawing lines out for what I thought I wanted to do, I saw that too much of the rear "crossmember" was going to be visible, so I altered the angle quite a bit. I'm happier with this than what I originally planned.

Looks real good. The cuts on the sides make it look much better. What did you paint it with? It looks textured.
Thanks! Actually, this is just Rust-Oleum flat black that I sprayed on to keep the rust at bay. The crappy cell-phone pic makes the finish look better than it is. I still have some grinding and sanding to do before I actually put a real coat of paint on it.
KO

[maduece]

[quote="hecull"]I finally got back around to working on this.

I put the receiver in last weekend, this weekend I was going to gusset up everything and bevel the outsides. Still a lot more I want to do, but here's an update. Please excuse the cell-phone pics. I managed to leave my camera at home again.

First had to make some gussets. I made a ton, both in 2" and 2.5". I made more than I needed, while I was cutting I might as well make some to have around.
http://buzzardluckfab.com/images/kdo/gussets.jpg


Dam you and that wonderful saw! I like the simple look and agree with just keeping the center shackle. So what was up with the portable not doing the job like you thought it would?

[akxj]

how come it's so wide???

[IH8RDS]

[s:6b8a83dcdc]Good[/s:6b8a83dcdc] Great job Kyle!! :cheers:

http://buzzardluckfab.com/images/kdo/bumper3.jpg

[hecull]

[s:49406bfbff]Good[/s:49406bfbff] Great job Kyle!! :cheers:
Thanks Scott!

how come it's so wide???

Not only does the extra width help to protect the tail lights, I'll be using the steel I got today to add some quarter panel protection after I hack off the quarter panels. Hmm, guess there's no reason to protect them then... Well, maybe it will save me in glass :)
I hope to have pics tomorrow to show what my evil mind has been up to.

The bender should be here in a couple weeks. That's when things are going to get interesting! :devil:
Kyle

[goXJ]

nice bumpers you guys made. robbs too.

:thumb: