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Old October 2nd, 2008, 06:51 PM   #1
jeepxj2007
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Default My rear bumper build

I have a 90 Wrangler, and am deciding to build a new bumper for the rear because I am trading off the one I currently have to a buddy, and I wanted something that I built, and something a little different than the plain jain bumper that seems to be everywhere. Here is what I am starting with:
Materials:
2x4 tube steel 3/16" thick (5 feet)
2x2 tube steel 3/16" thick (18 total inches)
2.75x4.5 plate 1" thick
2.5" plate 1/4" thick (30 inches)
2" plate 3/16" thick (2 feet)
2.5" pipe sch 40 (2 1/8" x4)
2.5 square tube ( 6 inches)

As you can see in the pics I am using the plain jane design that you see alot, but added a few things different. At the ends the 2x2" goes up and ends right where the fender flare ends and follows the same body line. The 2.5 pipe is welded all the way around on both sides to seal off the tube, but I think it looks neat, and different. I feel it gives the bumper more strength because it ties the front into the back in multiple places (hey if they do it on frames why can't it work on this?) The shackle mounts go all the way through the bumper, are welded on the front to the bumper, and welded to the 1/4" plate, then the plate will be welded to the back of the bumper, this 1/4" plate also serves as the middle man of mouting the bumper to the mounting brackets. I placed the Shackle mounts right in the middle of the frame rails, I figured this would be stronger than placing them in the middle, it would place less strain on the bumper itself and be pulling directly on the cheesy welds that hold the crossmember to the frame instead of applying force sideways. In the middle of the bumper I plan on welding in 2" reciever.

I still haven't decided what I am going to do with the bumper. I have a spindle and round tubing to build a swingout, but I hate the one I have now because it rattles and is annoying, I was thinking about just mounting my hi-lift on top of the bumper, but laying down so the tailgate still opens.

Please don't make fun of my crappy cuts! I did them with the plasma cutter at work today, second time ever doing it and my hand still isn't steady, and I ran out of welding wire so my shackle mounts are half-assed. Here are some pics...I will keep on posting updates...also are pics of my front bumper...let me know of some ideas/comments!




Here is the old bumper!

Front bumper!
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Old October 2nd, 2008, 06:55 PM   #2
gehtowheeler
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looks cool
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Old October 3rd, 2008, 05:23 AM   #3
pappa-g
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I like the rear. Looks very strong!
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Old October 4th, 2008, 02:11 PM   #4
jeepxj2007
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thanks for the comments!, Here are some updates, I worked on the bumper for about 2 hours today. I completely welded in all of the circles, and ground them smooth for the part you will see, I still need to clean the insides of them. I also welded the inside, top, and bottom of the side pieces. As for the shackle tabs, I made new ones at work, I wasn't happy with how the other ones turned out, the angles weren't exactly the same on them, and the shackle was too close to the bumper and I couldn't hardly get it on, I made longer ones, that look much butter I think, and drilled a 1 1/16" in them with the mag drill...here are some pics!


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Old October 8th, 2008, 07:59 PM   #5
jeepxj2007
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I now have the ends all welded in, the only thing left to seal off the bumper is the shackle mounts, and then to finish it I need to drill the 2" reciever pin hole, the mounting holes, and weld on the mounts, then some paint, I am putting 2 coats of chassis saver, and 2 coats of rustoleum hammer black.



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