'77 J10 Front Bumper Design

[HI-TECH REDNECK]

Well I got some measurements off the jeep, and decided to sit down and see what I could come up with for a bumper design using the two chunks of I-Beam I have laying around. This is pretty much the idea I have had in my head ever since I acquired the I-Beam. However I hadn't ever looked closely at the truck to figure out what everything was going to look like.

I'm pretty happy with it, the I-Beam is 60" long and I decided on a width of 70" to line up with the body how i wanted. so im going to have to add on to the ends of the I-Beam with either some from the rear bumper or other kinds of material. I haven't messed with this in the drawings yet, but I have some ideas in my head of how I can do that.

As you can see I have fitted a 2"ID x 1/4" wall receiver into the center of the bumper, which will pass all the way through the front crossmember in the frame. The mounting brackets are 1/2" plate and pass directly through the I-Beam to the front side, where the Shackle mounting holes are. I figure this way direct pulls on the Shackles will go right to the frame, instead of relying as heavily on the I-Beam itself. The brackets are notched to pass through the I-Beam so that there will be a notch for the Beam to push against the brackets should it take a front impact.

I probably will reinforce the beam to bracket mounting with some angle iron when I actually do build this, I dont see any real value in putting that in the drawing as its something thats easy to add without it being in the drawings....

I plan on bolting the brackets to the frame, which I still need to figure out the mounting hole locations. This might get reinforced with some welding, ill see how bolting it on goes at the time of installation then the beam will be welded to the brackets. the 2" receiver will pass thru the beam and the crossmember and be welded to both in as many places as it can be. I reinforced the end of the receiver tube with a 3/4" long peice of 3" O.D. 1/4" wall square tube steel.

well enough blabbering, heres the pics....
Front Frame and X-Member
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/frntframedimetric.jpg
Passenger Side Spring Shackle Mount
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/PSShkleisometric.jpg
Driver Side Spring Shackle Mount
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/DSshklisometric.jpg
Bumper Bracket & Shackle Mount
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/bumperbrktisometric.jpg
I-Beam Bumper
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/bumperisometric.jpg
Assembly View
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/bumpercstmview.jpg
here is the link to the rest of the pictures of it, i only posted a few teasers....
http://s151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/

and just because i know you guys like pics, here is my truck (before i took the rotten box off)...
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/PICT0072.jpg

http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/PICT0070.jpg

i need to get some more current pics of it, not having a camera makes it hard though....:banghead:
let me know what you guys think :thumbsup:

[HOOT]

HEY !!!!! You should warn us before posting such pics..We like pics but... WOW what a wreck.... What if the kids were in the room?!?!? I threw up a little....

I like the new bumper so far..

[Gambler68]

I think it bred with a late 70s toyota to get rot like that...

nice Solidworks designs! (assuming).

[BRUTUS]

Passenger Side Spring Shackle Mount
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/PSShkleisometric.jpg
Driver Side Spring Shackle Mount
http://i151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/Front%20Bumper/DSshklisometric.jpg


I think you need to rethink these two parts in particular. Yes you did design them but I don't think you have thought about actually making them. You at least need to go back in to Solidworks and add bend reliefs to the sheet metal feature because these parts will severly disfigure if they are cut/bent as you have shown (ask me how I know). The other side of this coin is that I don't think you have thought about actually bending these pieces. Do you realize that you will have to have one knife and two dies in your press in order to leave the center section straight? If it were me I would make two pieces out of each of these parts (I would use a dovetail design to tie the two parts together so that there is a mechanical connection that can be followed up with a weld)... I think you would be much happier with the fabricated results then.

Otherwise I like the design and overall integration of the bumper. It will definately be stout when it is complete.

[HI-TECH REDNECK]

thanks for the input brutus.
Luckily i dont have to make those spring shackles. they are the stock ones already on the truck. the only reason i made them in the drawing and put them in the assembly is because of that tab that laps along the side of the frame, which is why i need that cut out in the mounting brackets so the plate actually fits on the frame halfway decently. i see your point that it would be impossible to make them as i drew them, but since they are already made i dont need to worry about that. i just needed them there to take up space so i could work around them...

thanks again for the explanation, it gives me something to look forward to learning as i have not used or seen a press with the tools you described in action before. most of my fabwork experiences have been around people using torches, grinders, shopsaws, bansaws, and that kind of stuff. i have not seen a whole lot of sheetmetal bending yet (other then body's on vehicles out in the woods...haha)

I think it bred with a late 70s toyota to get rot like that...

nice Solidworks designs! (assuming).:)
this truck sat in central wisconsin feilds for at least 10 yrs with out being registered or getting current titles when it changed hands before i got it:eek:. i was finally able to get it titled and regisered in my name though:D. yeah its a little ugly....it doesnt have the bed on it anymore, i have a wood flatbed on it, so it has even more character now, haha. Yes that is SolidWorks.

[DrveJeepDrnkBeer]

Man, and I thought my parts J-10 was rusty! Can't wait to see the bumper tho...

[HI-TECH REDNECK]

Man, and I thought my parts J-10 was rusty! Can't wait to see the bumper tho...
suprisingly the frame does not have any major rot, only surface rust.

[noflyzone]

Hey, The truck is straight! Please post current pictures. They should be quite motivational. I thought I was going to have a tough time with mine.

[HI-TECH REDNECK]

yeah the frame is very solid i thought. i should put up a new thread on the history of this truck, as i actually got to meet a few of the previous owners while trying to get the title straightened out for it. its got an interesting history that dates a ways back....hopefully i havent forgotten too many of the details:confused: ....

these arent super current, but current as of the end of this past summer(minus the ones labled junior year of high school).
http://s151.photobucket.com/albums/s160/HI-TECHREDNECK/random%20vehicle%20pics/1977%20J-10/

currently it has a bunch of lumber on the back under a tarp, its sitting on jackstands with wheels and tires of different sizes with no air in them bolted to the axles, and burried in the snowbank in the driveway. so not realy worth getting current pics, but our schools wheeling club is having their spring opener the 5th of april, so hopefully it will get drug out of the snowbank and get a new flexplate/starter/ and maybe a low range unit before the 5th. oh yeah, and also might have a line on some 35 gumbos (which are actually like 33's, which i can fit stock) which should solve my lack of quadra trac friendly tire issues....:banghead: then hopefully it will be time to :drivin: :fsj: which is :thumbsup: and makes me go :D . (you guys have some of the best smilies of any forum im on i think....haha)