Jeep Bumper/Completed 4/14/07

[Bronkzilla]

One of my coworkers has a Jeep YJ (I think).. He was looking for a rear bumper and I offered to build it so he wouldnt spend 700+ on one. I spent about 65 bucks for the steel so far and have some scrap I can use for the rest of the bumper. Most of the steel money went to the main 2x4 which is a hefty 1/4" thick.. He purchased the hinge and d-ring plates at rockstomper. It should come out to about 2 bills for the whole thing including d-rings and 2 jerry cans.. I havent whored out any pictures in a bit so I figured this would work... The idea can be stretched out and made into a bronco bumper. Here are some pics:

Steel. Some purchased, some scrap...
http://bronkzilla.com/images/BlackPearlBumper/3-29-07/IMG_0729.JPG

These are the d-ring plates.. I cut a 1/4" thick plate and drilled a hole in the center. I then welded it to the back of the d-ring plate. I plan to cut a hole through both sides of the bumper and push the plate in through the back. I will then weld the front to the bumper and have more contact area in the back to weld.. Might not make sense but it is clear as day in my head..
http://bronkzilla.com/images/BlackPearlBumper/3-29-07/IMG_0731.JPG

Something like this.. Just imagine the d-ring thing going through the bumper.. The 2 pieces of steel next to it will be the mounting brackets.
http://bronkzilla.com/images/BlackPearlBumper/3-29-07/IMG_0732.JPG
http://bronkzilla.com/images/BlackPearlBumper/3-29-07/IMG_0733.JPG

Its a bit windy right now so I am going to work on it tomorrow and this weekend. Heres is a layout of some of the pieces..
http://bronkzilla.com/images/BlackPearlBumper/3-29-07/IMG_0739.JPG

A couple of extra things i plan to do is to add fittings so it can be used as an air tank in the future. Since the hinge doesnt go all the way through the bumper i plan to weld a tube from top to bottom and then slide the hinge in and weld it.. Should make it plenty strong..

Any thoughts, ideas or suggestions are greatly appreciated as always.. :whiteflag

[Bronkzilla]

Heres a sketch my coworker made of what he wants..

http://bronkzilla.com/images/BlackPearlBumper/3-29-07/sketch.gif

[Bronkzilla]

Some more pictures..

it was almost a shame to have to grind these down.. I v'd the hell out of the steel so that even with the welds ground down it would still have more than enough to hold it in.. took longer but it should work nicely..
http://bronkzilla.com/images/BlackPearlBumper/3-30-07/IMG_0746.JPG

gone.....
http://bronkzilla.com/images/BlackPearlBumper/3-30-07/IMG_0747.JPG

looks like yesterdays picture but now its all welded up.
http://bronkzilla.com/images/BlackPearlBumper/3-30-07/IMG_0748.JPG

[Bronkzilla]

More pics...

Sleeve for the hinge.. The sleeve gets welded to the top and bottom of the bumper so that its not relying on the single weld around the top..
http://bronkzilla.com/images/BlackPearlBumper/3-31-07/IMG_0752.JPG

These Bosch (sp?) metal cutting blades are awesome... They cut through 1/4" steel pretty fast. I just drill a hole at opposite corners and used a piece of 1" thick wood so that the blade wouldnt hit the other side of the bumper.. Highly recommended.
http://bronkzilla.com/images/BlackPearlBumper/3-31-07/IMG_0755.JPG

mounting and d-ring brackets welded in..
http://bronkzilla.com/images/BlackPearlBumper/3-31-07/IMG_0771.JPG

took me a while to figure out how to level out the hinge in order to weld it in.. i tacked that scrap piece to the left then one to the right and it held it tight as i welded it..
http://bronkzilla.com/images/BlackPearlBumper/3-31-07/IMG_0772.JPG

here is the bottom sleeved area.
http://bronkzilla.com/images/BlackPearlBumper/3-31-07/IMG_0773.JPG

should keep this from happening. hahaha although i doubt he will be pivoting his truck around a tight turn with his carrier like i did..
http://bronkzilla.com/images/BlackPearlBumper/3-31-07/TH410627.JPG

top..
http://bronkzilla.com/images/BlackPearlBumper/3-31-07/IMG_0774.JPG

last picture.. i think im about to run out of argon/co2... more progress during the week..
http://bronkzilla.com/images/BlackPearlBumper/3-31-07/IMG_0775.JPG

[Blanco]

Wow! :awesome_dude:
I cant wait to see the completed project.

:16:

[hidesertwheelin]

Let us know how that hinge holds up. I am thinking about mounting them on my bumper.

[CJ7on33's]

Nice man your welds look awesome. I need to start welding some more to get up to speed been a while. But i like the bumper

[Bronkzilla]

this new latch should work much better..
http://bronkzilla.com/images/BlackPearlBumper/4-02-07/latch.jpg

[bigbroncojeff]

good thinking on sleaving the hinge like that... that spare tire out that far going to kill his departure angle?? looks like it will be almost even with the bottom of the bumper

[Bronkzilla]

departure angle is overrated... if anything it will make the landing smoother..`

http://wt4x4.net/trips/hollister/MBB/54299067Vzbrut_ph.jpg

[Blanco]

:20:

[Bronkzilla]

damn.. i forgot about the bumper all week.. better finish it tomorrow..

[79F150]

Nice work Raff.:awesome_dude:

[Bronkzilla]

got some gas and finished the jerry can holders..

http://bronkzilla.com/images/BlackPearlBumper/4-07-07/IMG_0783.JPG

primed them so i dont have to sand off the surface rust later..

http://bronkzilla.com/images/BlackPearlBumper/4-07-07/IMG_0784.JPG

i bought a 5" orbital sander today.. Used it to get all the stuff the steel shop puts on the steel to keep it from rusting.. took forever to remove..

http://bronkzilla.com/images/BlackPearlBumper/4-07-07/IMG_0787.JPG

primed it and cleaned up the tire carrier..

http://bronkzilla.com/images/BlackPearlBumper/4-07-07/IMG_0792.JPG

primed that and put it all away for now.

http://bronkzilla.com/images/BlackPearlBumper/4-07-07/IMG_0793.JPG

i had planned to work on it tomorrow but i forgot about the easter bbq we are having.. maybe during the week..

[MUDMAD]

Looks really good Raf. Welds look a lot better than the ones I saw at Hollister, remember? Haha:rofl: Hint-Radius Arms. Looks like you've been quite the busy welder over the years.

[Bronkzilla]

yeah. those were scary.. it held though..

[MUDMAD]

yeah. those were scary.. it held though..

Sometimes it's not how pretty they are, it's how functional they are, and those were functional. Wish I were closer to you so I could have you help me when I build my bumpers. You do very nice work. Why don't you and Crawler start your own fab store? That would be some quality products coming out of that store. Then maybe you could get that other fab monster we have here, um, you know that one don't you, the one with those tricked out rock sliders. Wow, the genius in those are great.

[Bronkzilla]

I dont think i could do this for a living.. At least not with the tools i have right now. I can do it once in a while for fun...

[bigbroncojeff]

looks good

[Bronkzilla]

Finished up the bumper just now.. Here are some pictures..

Rear
http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0794.JPG

Latching system.. I think it kicks ass..
http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0795.JPG

http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0796.JPG

http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0797.JPG

http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0809.JPG

side shot. we decided to angle the tire back just a bit at the top. his friend cut out the plate with a cnc laser..
http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0801.JPG

front..
http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0804.JPG

i put my hi-lift, jerry cans and d-shackles in it for $#!+s and giggles.. his hi-lift will be smaller..
http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0805.JPG

all it needs are the wheel studs and its done..
http://bronkzilla.com/images/BlackPearlBumper/4-14-07/IMG_0806.JPG

i know its alot of pictures but it might help someone out looking for ideas on how to fab up their own bumper.

[Blanco]

I normally Frown at any square tubing work, But in this case it looks Killer! :7:

I cant wait to see it installed. :cheers:

I wanna see how much you killed the Departure angle as Jeff Mentioned. :humm_smilie:

[Bronkzilla]

thanks...


here is the before shot.
http://bronkzilla.com/images/BlackPearlBumper/4-16-07/BEFORE%20AND%20AFTER/BEFORE%20BUMPER.jpg

and after.. he said it dropped 3/4"..
http://bronkzilla.com/images/BlackPearlBumper/4-16-07/BEFORE%20AND%20AFTER/AFTER%20BUMPER.jpg

some misc pictures...

http://bronkzilla.com/images/BlackPearlBumper/4-16-07/IMG_9349.jpg

http://bronkzilla.com/images/BlackPearlBumper/4-16-07/IMG_9350.jpg

http://bronkzilla.com/images/BlackPearlBumper/4-16-07/IMG_9352.jpg

http://bronkzilla.com/images/BlackPearlBumper/4-16-07/IMG_9353.jpg

http://bronkzilla.com/images/BlackPearlBumper/4-16-07/IMG_9354.jpg

http://bronkzilla.com/images/BlackPearlBumper/4-16-07/IMG_9366.jpg

more pictures here: http://bronkzilla.com/images/BlackPearlBumper/4-16-07/

ill be sure to get updated pictures up when he gets it painted and slaps a spare tire on it..

[Blanco]

Looks :awesome_dude: But, Why would you mount it before painting it?

I find it much easier to paint part before they're mounted. :m2c:

[Bronkzilla]

cause he had to drill the holes to mount it up and make sure nothing needed to be changed before painting it.. Its gonna come off for paint...

[Blanco]

cause he had to drill the holes to mount it up and make sure nothing needed to be changed before painting it.. Its gonna come off for paint...

OK that makes better sence now! :)
Looking forward to those paint & spare mounted Pics. :16:
Hey, How about getting that Jeeper on TWW with us Raf? :shrug:

[Bronkzilla]

nah

[Blanco]

nah

:eric[1]:

[Bronkzilla]

right back atcha'...

[CJ7on33's]

how much would a bumper like that cost to get made?

[MUDMAD]

how much would a bumper like that cost to get made?

$1,500.00



Raf, that's one nice bumper you built there. Do you know about how much it weighs? Also, how thick is the bumper, 1/4, 3/8? Sorry, you probably already posted this stuff somewhere. Nice job.

[Bronkzilla]

not sure on the cost. i bought some steel and used some scrap. he bought the hinge and latch online.. id say maybe 200 bucks total...

it weighs 113 pounds altogether... the main bumper is 1/4" thick. The rest is mostly 1/8" square/rectangle tube and 1/4" plate and angle iron..

[bigbroncojeff]

if he doesn't start armor-all-ing his flares tey will match the primer of the bumper

looks good raf.... needs something more than the bungies for the cans though

[Bronkzilla]

yeah, that was just what he had at hand...