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Old February 27th, 2012, 11:05 PM   #1
Black Sheep
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Default XJ Rear Bumper Build

Welding is pretty new to me but I decided to try my hand at hacking a bumper together for my 99 XJ. Started with some 1/4 plate and 2x4 tube





Added a few gussets for piece of mind



Then I opened up the frame channel and tried a test fit





The main bumper is 2x5x3/16", 66" long. I wanted the bumper to follow the curve of the rear hatch so I notched the 2x5 22" in from each end, pulled it together and welded it back up. Worked out perfect. I then cut the tapers into the end of the 2x5, folded the bottom up and welded everything up.

With the tie-ins on the Jeep I tacked the bumper to the them, added a receiver and finished welding up what I could





With the bumper back on the Jeep I added some side bars to it then got it ready for paint



Final product


Last edited by Black Sheep; February 27th, 2012 at 11:10 PM.
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Old February 28th, 2012, 10:14 AM   #2
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Nice work

What kinda welder you using?
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Old February 28th, 2012, 10:48 AM   #3
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A 110 Lincoln Pro Mig 135. Nothing fancy. I'd like get my hands on a 180 Dual Lincoln
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Old March 3rd, 2012, 09:23 AM   #4
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looks good bro!! would you ever consider building one for someone?
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Old March 5th, 2012, 05:28 PM   #5
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Sure. It might take me a while to complete tho
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Old March 5th, 2012, 06:37 PM   #6
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looks great
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Old March 22nd, 2012, 02:17 AM   #7
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Yeah man that looks solid!
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Old March 22nd, 2012, 08:17 AM   #8
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Nice!

Your license plate's all fucked up though....
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Old March 23rd, 2012, 09:31 PM   #9
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Thanks! I'm ready to test it out. Hopefully it won't be much longer.
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Old May 28th, 2012, 09:21 PM   #10
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Bumper looks good. It was a good time wheeling with you on Saturday. Hope you didn't have much more carnage after the broken window and rear pinion on your buddies xj.
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