A few pics from my Front bumper build - Great Lakes 4x4. The largest offroad forum in the Midwest

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Old July 1st, 2007, 07:43 PM   #1
Kawierider
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Default A few pics from my Front bumper build

I've been wanting to build a bumper since I bought the jeep like 4 years ago. I started building this a few months ago during school and am finally getting around to finishing it up. I spent a few nights working on the bumperin the last week and heres the results:

Got the 5x2x.25 square tube cut, boxed, and all of the welds ground. Should be Airtight when I put the Air fittings in it since I ground out and re-welded any area that had pin-holes......



Close-up pick of the end......



D-rings and my 110Mig um....prowess......



Finished and welded to The tow-hook brackets I made when I bought the jeep




Mounted up after I primed and painted with two coats a peice.




I might add a little mini-stinger to the front to protect the grill and whatever lights i'm gonna put on it but that will come later.....future additions might include a receiver mount also.


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Old July 1st, 2007, 08:56 PM   #2
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I really really hope you didn't just face weld the shackle mounts on. Let alone only using a 110v MIG that you probally didn't bother to champer the edges of what you were welding. Also, you'll want to re-enforce the mounting system if you plan to do any pulls.
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Old July 1st, 2007, 09:10 PM   #3
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x a billion!

Otherwise looks good. But i would DEF> get it welded with a 220 and chamferd endges on the Tabs.
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Old July 2nd, 2007, 09:38 AM   #4
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It's awesome that you are building your own bumper and it looks pretty good. I agree that those tabs need to be redone with a bigger welder. The chances of you getting great penetration on the tabs that thick with 110 is pretty small.
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Old July 2nd, 2007, 02:19 PM   #5
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Quote:
Originally Posted by Rocky View Post
I really really hope you didn't just face weld the shackle mounts on. Let alone only using a 110v MIG that you probally didn't bother to champer the edges of what you were welding. Also, you'll want to re-enforce the mounting system if you plan to do any pulls.
I HEAVILY chamfered all welds on this bumper....at least .25" (only about 1/8th for the 1/4in. brackets but I did both sides), on the D-rings I preheated with Mapp, went 2 slow passes over, ground down and then did a third.

Time consuming, but it should be plenty strong.

Those 1/4in brackets I mounted to use 4-bolts per side(basically same as a rusty's and others, tow hook brackets) I used 1/2in. Grade 8 hardware on each bolt. They all have at least a 1x1 block on them to distribute the load to the uni-body so they dont pull through.

I've been abusing the hell out of those brackets for about 4 years now and none of the holes showed signs of being oblong, and the base unibody steel showed no signs of being bent. Now, they are tied together with the bumper itself which will only increase strength.

thanks for the input....I may bring it to the office and use our 220mig.

Last edited by Kawierider; July 2nd, 2007 at 02:42 PM.
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Old July 2nd, 2007, 07:32 PM   #6
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i don't wana sound like i'm bashing your stuff as you did a great job with that bumper. Just you can NEVER be to safe with welds that are going to see heavy abuse and tons of pulling force.

I welded my front bumper with a 110mig with .30 wire and it did good, but for extra security I had my brother run over it with a 220 stick. Would it have been fine with the 110? I beleive so since i did a few passes and went very slow, but you can't put a price on saftey and i would feel really bad if it came loose and hurt someone.

Keep up the good work though as fabing your own parts is fun and gives you a good feeling of acomplishment.
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Old July 2nd, 2007, 10:42 PM   #7
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Quote:
Originally Posted by Kawierider View Post
I HEAVILY chamfered all welds on this bumper....at least .25" (only about 1/8th for the 1/4in. brackets but I did both sides), on the D-rings I preheated with Mapp, went 2 slow passes over, ground down and then did a third.

Time consuming, but it should be plenty strong.

Those 1/4in brackets I mounted to use 4-bolts per side(basically same as a rusty's and others, tow hook brackets) I used 1/2in. Grade 8 hardware on each bolt. They all have at least a 1x1 block on them to distribute the load to the uni-body so they dont pull through.

I've been abusing the hell out of those brackets for about 4 years now and none of the holes showed signs of being oblong, and the base unibody steel showed no signs of being bent. Now, they are tied together with the bumper itself which will only increase strength.

thanks for the input....I may bring it to the office and use our 220mig.
Just wanted to double check, I've seen some scary shit out there.
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Old July 2nd, 2007, 10:48 PM   #8
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Quote:
Originally Posted by Plato2k5 View Post
i don't wana sound like i'm bashing your stuff as you did a great job with that bumper. Just you can NEVER be to safe with welds that are going to see heavy abuse and tons of pulling force.

I welded my front bumper with a 110mig with .30 wire and it did good, but for extra security I had my brother run over it with a 220 stick. Would it have been fine with the 110? I beleive so since i did a few passes and went very slow, but you can't put a price on saftey and i would feel really bad if it came loose and hurt someone.

Keep up the good work though as fabing your own parts is fun and gives you a good feeling of acomplishment.


Which 110 do you use/How do you like it?
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Old July 3rd, 2007, 01:05 AM   #9
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I have some Lincoln mig that can accept gas. I'll get the amp and stuff from it in the morn.

I like it, does great. Does great welds, and I've fabed alot of stuff with it and welded to my 88 YJ. Wish i had a 220 though. The max i have and will ever weld with the 110 is 1/4" plate. I think i used .035 wire for that to for more penetration. This was WITHOUT gas hookup. With the gas you cannot weld as much.
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Old July 3rd, 2007, 02:15 AM   #10
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did you make the D ring tabs ?? or buy them ?? I made mine and even taking my time cutting them out with the torch nice and straight and about 30 min of grinding on each one they still didnt look that good. But yea nothing beats making a set of bumpers yourself and saving 3/4 the cost of bought ones
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Old July 3rd, 2007, 10:47 AM   #11
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i have never really beena fan of D-rings. I just use 10,000lb hooks on the sides of the frame at the front.
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Old July 3rd, 2007, 12:47 PM   #12
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I did all the welding on my bumber with a 110, d-rings included. I have pulled out and been pulled out a ton of times using them, have yet to have a problem. A 110 will do a solid job if you take the time to do it right.

http://www.greatlakes4x4.com/showthread.php?t=35544
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Old July 3rd, 2007, 07:41 PM   #13
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IMO the tow hook/D-ring mount should never be welded on. The d-ring mount and the bumper mount should be one piece of steel and have the bumper weld to that. therefore all of the stress goes to multiple grade 8 bolts and the vehicles "frame" instead of a weld.

great lookin bumper btw!
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Old July 3rd, 2007, 09:22 PM   #14
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IMO the tow hook/D-ring mount should never be welded on. The d-ring mount and the bumper mount should be one piece of steel and have the bumper weld to that. therefore all of the stress goes to multiple grade 8 bolts and the vehicles "frame" instead of a weld.

great lookin bumper btw!
IMHO it just depends on how competent you are with a welder, and if you utilize the whole structure of the tube your welding to.
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Last edited by Monkeyevil; July 7th, 2007 at 02:32 PM.
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Old July 6th, 2007, 09:17 PM   #15
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Quote:
Originally Posted by Plato2k5 View Post
I have some Lincoln mig that can accept gas. I'll get the amp and stuff from it in the morn.

I like it, does great. Does great welds, and I've fabed alot of stuff with it and welded to my 88 YJ. Wish i had a 220 though. The max i have and will ever weld with the 110 is 1/4" plate. I think i used .035 wire for that to for more penetration. This was WITHOUT gas hookup. With the gas you cannot weld as much.
I dont have the gas option....so it's not an option . I've considered going to the 035 wire, may give that a go-round next time I start having fun. I would like a 220 welder but that is gonna have to wait til I move out and get a large-enough shop for one.

the next fab project will either be a rear bumper/tire carrier or putting in my 8.8 which ever comes first.
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Old July 6th, 2007, 09:18 PM   #16
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Quote:
Originally Posted by Muddinguy View Post
did you make the D ring tabs ?? or buy them ?? I made mine and even taking my time cutting them out with the torch nice and straight and about 30 min of grinding on each one they still didnt look that good. But yea nothing beats making a set of bumpers yourself and saving 3/4 the cost of bought ones
I would have done them myself if I would have had a torch, I bought them from jeepers creepers for like 10 bucks, I think they were water jetted.
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