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Old December 17th, 2010, 11:04 AM   #1
ahansen0410
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Default ZJ Bumper Build

I couldnt see spending the money on a heavy duty bumper like the ones on the market, so I I decided to make my own. I will have a whopping 30 bucks plus hardware into it when its all said and done.

I started out doing a search to find out what other people had done. I came up with this link http://www.jeepsite.net/jeep_story11.html and I liked what they did. They used 7" channel for theirs, but I found some 8" channel that will work just as well. There are a few things I am going to do different like add some D-ring mounts and I think I have a better idea for mounting it also.

I took some measurements and came up with a design for it to wrap around the front like I want it to. I designed it in CAD and here are the dimensions and angles i came up with.

bumper.pdf

If you are interested in the dimensions, and this link doesnt work, PM me and I will get you the drawing.

I took about a 7'-0" length of 8" channel, that I found for 30 bucks. The rest of the material I used were scraps laying around my pole barn and work.

After I got everything cut and tacked together, this is what I have.

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I am going to put it up to the jeep tonight and see how it fits before I weld it up the rest of the way.

I will continue to post pictures as I go. Let me know if you guys have any ideas as I go along!
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Old December 29th, 2010, 07:30 AM   #2
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I fit it up to my Jeep the other day and fit exactaly like I wanted it to. I have it all welded and sanded the rust off and smoothed out. I have to grind the welds down now and give it a finished look. I will be geting measurements for where the mounts need to be welded on and the d-ring monuts I mades the other day.

Should have more pictures up today.
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Old December 29th, 2010, 08:14 AM   #3
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Old December 29th, 2010, 08:41 AM   #4
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Nice progress, final fit pics would have been cool.

Anything other then tow points? recessed fog lamps?

Don't forget the flag mount....
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Old December 29th, 2010, 09:24 AM   #5
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Definitely watching this one. I have a 94 zj with the bumper being held on with zip-ties. X2 on the flag mount. You should put some thought into cutting the sides at an angle to allow for increase in tire size in the future. The same concept as trimming the plastic bumper for clearance.
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Old December 29th, 2010, 05:03 PM   #6
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hey let me know if you need any help getting that thing mounted or anything. Here is a link to my build
ZJ bumper build - Great Lakes 4x4. The largest offroad forum in the Midwest

BTW Im in Lakeview not farm from you.
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Old December 29th, 2010, 05:47 PM   #7
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Thanks spudy. I was wondering how to mount the bumper to the unibody.
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Old December 29th, 2010, 06:05 PM   #8
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if you have any questions after you read my build thread message me on here.
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Old December 29th, 2010, 07:27 PM   #9
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I'm looking to d a mix of spudy's mounting and ahanson's bumper. I want to keep it close to the body for now.
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Old January 1st, 2011, 09:21 AM   #10
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well it looks like a am going to build this bumper and not spudy bumper
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Old January 1st, 2011, 01:12 PM   #11
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best of luck :-)
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Old January 1st, 2011, 05:18 PM   #12
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thanks man your bumper is bad ass but i am going on the cheap and for 7f long and 8in wide is metal is 60 bucks
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Old January 3rd, 2011, 03:59 AM   #13
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I like the looks of yours too spudy. I wanted to do something kind of like that, maybe in the future when I get a winch but thats a ways down the road.

Newdodge, sorry I havent gotten a chance to call you, I will do that tonight probably. I've been busy with the holidays.
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Old January 3rd, 2011, 04:08 AM   #14
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I will get pictures up on wednesday of how I am mounting the bumper. I am going to use 2x4 - 3/16" tubing. if you cut the sheet metal around the openings of the unibody like spudy did and wrap the 2x4 tubing a few times with a hammer it slides right in. I am going to slide it in as far as i can and mark for mounting holes. then i am going to use some 12 gauge galvanised steel cut at 4"x6" and sandwich each side of the unibody and tube steel and run bolts all the way though.

Sorry if that is hard to picture but i will get pics up on wednesday.
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Old January 3rd, 2011, 04:16 AM   #15
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Quote:
Originally Posted by atvextreme View Post
Nice progress, final fit pics would have been cool.

Anything other then tow points? recessed fog lamps?

Don't forget the flag mount....
I have put some thought into recesed fog lamps, but i think that will be something i do in the future if i do. definatly will have a flag mount on there.


Quote:
Originally Posted by Marine_mike View Post
Definitely watching this one. I have a 94 zj with the bumper being held on with zip-ties. X2 on the flag mount. You should put some thought into cutting the sides at an angle to allow for increase in tire size in the future. The same concept as trimming the plastic bumper for clearance.
I am going to cut the sides for more clearance, I just want to get it mounted first. it will have 2 cuts like in the bumper i got the idea from and on the top cut i want to follow the line of the fender. i just want to make sure i get it in the right spot after mounted.
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Old January 3rd, 2011, 04:31 AM   #16
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here is a progress picture. getting all of the welds cleaned up and the rust sanded off with an abrasive disk.

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Old January 3rd, 2011, 07:51 AM   #17
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looks good man...
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Old January 3rd, 2011, 11:48 AM   #18
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what do you guys recomend for the flag mount? I've havent been many places that I needed one, so its never been something I've checked out.

if you guys could send some pictures or something it would be awesome!
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Old January 3rd, 2011, 03:33 PM   #19
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All you need for a flag mount is a half inch hole and room to put the nut on the bottem. Depending on how tight it is just drill a hole or 2 (one for each side) on the top edge of the channel. Or you could weld a tab or 2 off the front.
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Old January 3rd, 2011, 03:45 PM   #20
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I threaded a male air connector into my bumper. Air chuck on flag. Dune ready,with no tools.
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