View Full Version : ZJ Rear Bumper build

02-12-2012, 05:51 PM
I've been running with no bumpers for a few months now after I broke the mounts on the rear out at the boulders. Finally, thanks to members of this board pointing me in the right direction for cheap rems, I picked up some steel and started on the rear.

I cut up the stock hitch and welded it between 2 pieces of 2x4x.188. Welded a few nuts inside and slipped that into the frame rails. That gave me about an extra 5" to the bottom of the hitch.

http://farm8.staticflickr.com/7019/6831437723_7398cc9a0a.jpg (http://www.flickr.com/photos/67113766@N02/6831437723/)
photo (1) (1024x765) (http://www.flickr.com/photos/67113766@N02/6831437723/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

Then I picked up some plate and started skinning it.

http://farm8.staticflickr.com/7032/6831437473_bc0bb92a0f.jpg (http://www.flickr.com/photos/67113766@N02/6831437473/)
SAM_0394 (1024x576) (http://www.flickr.com/photos/67113766@N02/6831437473/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

http://farm8.staticflickr.com/7174/6831437591_385dc8438a.jpg (http://www.flickr.com/photos/67113766@N02/6831437591/)
SAM_0398 (1024x576) (http://www.flickr.com/photos/67113766@N02/6831437591/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

So then I pulled the bumper back off and cut out the remaining pieces. Wish I had a plasma cutter, this bumper took 22 cut off wheels.

http://farm8.staticflickr.com/7053/6866555817_c90ce39231.jpg (http://www.flickr.com/photos/67113766@N02/6866555817/)
SAM_0403 (http://www.flickr.com/photos/67113766@N02/6866555817/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

http://farm8.staticflickr.com/7058/6866556637_5fe3fa8e75.jpg (http://www.flickr.com/photos/67113766@N02/6866556637/)
SAM_0405 (http://www.flickr.com/photos/67113766@N02/6866556637/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

Tacked the remaining pieces on.

http://farm8.staticflickr.com/7205/6866553331_de3c004d4c.jpg (http://www.flickr.com/photos/67113766@N02/6866553331/)
SAM_0412 (http://www.flickr.com/photos/67113766@N02/6866553331/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

Welded all the seams inside and out and ground them down.

http://farm8.staticflickr.com/7184/6866552467_63ba426b2d.jpg (http://www.flickr.com/photos/67113766@N02/6866552467/)
SAM_0411 (http://www.flickr.com/photos/67113766@N02/6866552467/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

Hit it with a coat of flat black for now.

http://farm8.staticflickr.com/7200/6866553955_50dec8e6e4.jpg (http://www.flickr.com/photos/67113766@N02/6866553955/)
SAM_0414 (http://www.flickr.com/photos/67113766@N02/6866553955/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

http://farm8.staticflickr.com/7202/6866554617_a35e67fdf9.jpg (http://www.flickr.com/photos/67113766@N02/6866554617/)
SAM_0415 (http://www.flickr.com/photos/67113766@N02/6866554617/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

I am pretty happy with it. There are some grinder marks and low spots but for my first fabrication project I think it came out pretty good.

I guess now it's time to start on the front.

http://farm8.staticflickr.com/7046/6866555249_4398679c9b.jpg (http://www.flickr.com/photos/67113766@N02/6866555249/)
SAM_0416 (http://www.flickr.com/photos/67113766@N02/6866555249/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

02-13-2012, 12:12 PM
Looks solid man! Put some recovery points on that bad boy!


02-13-2012, 09:30 PM
Thanks! I was going to put recovery points tied in to the 2x4 going into the frame but I always just use my hitch and don't really see the benefit. The front will have recovery points for sure.

02-19-2012, 09:27 PM
Got started on the front this weekend.

3/8" cold rolled plate for the mounts. Slid them into the unibody, marked the holes for the existing recovery point brackets, drilled 1/2" holes and welded 1/2" grade 8 nuts to the backs.

Then I mounted them in the frame and tacked them to the nut strip that runs over a foot back into the frame for the skid plate, crossmember, and sway bar bolts. Once the bumper is all tacked together i will take it off to finish weld. It will make removing the bumper more work but if I rip the front bumper off the whole front clip is coming with it.

Welded a piece of 6x4x3/8 angle I had in between and notched it for recovery points. Made some recovery points out of a 3/4"x2.5"x12" cold rolled bar. This makes up the frame of the bumper and is plenty strong. I will make the "skin" out of 10ga plate around this frame like I did in the rear.

The cuts were easy with a chop saw and a 10" cutoff wheel. Although, I did catch the dust collection bag on fire. The 7/8" holes were a pain to drill.

Close up of the welds. I don't think these are going anywhere.

The bottom of the radiator support will be reinforced with 1/4" angle and tied in to the bottom of the bumper skin. I will also plate from the outside of the frame rails where the bumper mount holes are to that piece of angle to tie it all together and sandwich the unibody. I think I have it figured out in my head how to do all this while keeping the bumper removable.

02-20-2012, 05:30 AM
lookin good!

My Green Jeep
02-20-2012, 08:54 AM
Thread moved per request of SBrach :)

02-25-2012, 06:19 PM
Made some progress on the front today.

http://farm8.staticflickr.com/7069/6783985548_f1ca74cba4.jpg (http://www.flickr.com/photos/67113766@N02/6783985548/)
Untitled (http://www.flickr.com/photos/67113766@N02/6783985548/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

http://farm8.staticflickr.com/7047/6783987012_5534ef9b77.jpg (http://www.flickr.com/photos/67113766@N02/6783987012/)
Untitled (http://www.flickr.com/photos/67113766@N02/6783987012/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

http://farm8.staticflickr.com/7057/6783986140_edff7be864.jpg (http://www.flickr.com/photos/67113766@N02/6783986140/)
Untitled (http://www.flickr.com/photos/67113766@N02/6783986140/) by sbrach57 (http://www.flickr.com/people/67113766@N02/), on Flickr

Cutting all this out with an angle grinder is getting old! How do I convince my wife that she wants me to buy a plasma cutter.

02-25-2012, 06:29 PM
Looks really good!

02-26-2012, 05:56 AM
I like it. Want to build one for my ZJ??? LOL

02-26-2012, 08:59 AM
In defense of rear points (no I don't have them either), it makes a good second connection point if you are using a snatch block

02-26-2012, 10:44 AM
Good point, it wouldn't be too hard to add them in the future. I am going to add a swing out tire carrier once i step up a tire size so I will probably add a couple of recovery points then.

03-11-2012, 06:21 PM

Got the front bumper done.

On to the next project.