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Old 01-27-2008, 11:14 PM
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sac_waggon sac_waggon is offline
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Rear bumper build

I posted a few pics of the rear bumper that I had made right before I went on a snow run. After getting several responses for more detailed pics, I decided to do a bit off a write-up. The bumper loosely follows the design of the Cliffhanger bumper that is sold by BJ’s Offroad. I considered buying one from them but it wasn’t exactly what I wanted. Also, I really wanted to build it myself. The lower portion of my rear fenders were pretty rusty so I trimmed them off and plated in the gap. I wanted some sort of rock slider to go where the fender material was so I incorporated it into the bumper.
I guess I will start with the two recovery points that are built into the bumper. I took two pieces of ½”X4” flat plate and welded them together to make 1”X4” plate. Then using a plasma cutter, I cut through the 2”X6” tube that is the main rear piece. The 1”X4” goes through the 2”x6” and is welded on both sides. The 1”X4” plate is bolted to some brackets that are bolted to the frame and then also serve as the recovery points. The 2”X6” tube is 1/8” thick as is most of the other material used. The rock slider portions are the same material as the main rear piece. To connect the rock sliders to the frame, I used 1 1/4” square tube that goes all the way through the 2”X6” tube. I plated in the outer hole and ground it off smooth. 4”X ¼” angle is used to secure the 1 1/4” square tube to the frame just behind the rear spring mounts. I was a bit concerned about the rock slider only being supported in the middle and at back where it is welded to the main bumper, but when I used my shinny new high lift jack to get the rear driver side tire all the way off the ground, my concern quickly diminished. Besides, rarely will a rock come up that close to the back tire. The hinge is the only piece that I didn’t fabricate myself. I bought it from AtoZ fabrications.
http://www.atozfabrication.com/catalog/tirecarrierhingekit-p-34.html?zenid=413897c9e0cd12ef0c8fdaaec48e5a2e
Let me tell you, it is nice. A premade, high quality set-up that is ready to go. The zerk fitting is something that I added just because I thought it would be cool to have
The swinging tire carrier part is pretty much a copy from BJ’s. There is only so many ways that you can mount a tire, two gas cans and a high lift jack. My only requirement was that both lights and the license plate needed to be fully visible from a reasonable following distance. I didn’t want to give California’s finest and reason to stop me. Also I chose to put the gas cans on the driver side for two reasons, they are heavy and I am lazy. That way trailside refueling can be accomplished with the old Oklahoma credit card, just siphon away. Because of where the spare tire is mounted, a bit of a blind spot has been created, but since this is not my daily driver, I felt it was a compromise that I could live with.
That’s about it. Here are some pics to check out. Enjoy…
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Old 01-27-2008, 11:19 PM
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sac_waggon sac_waggon is offline
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Some more pics. My two daughters are my reason for buliding this rig. At our house we say FSJ stands for Family Size Jeep.
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Old 01-27-2008, 11:32 PM
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Wow that looks really good. Just wondering though is there a chance of the spring shackle hitting the frame mount when you get flexed out? It just looks kinda close in the pics.
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Old 01-27-2008, 11:52 PM
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Nicely done!! any thoughts of making a few available?
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  #5  
Old 01-28-2008, 01:09 AM
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Looks very nice! Could you post up some pics of where you cut out the fenders? I am thinking about doing that to mine but not sure if I will like how it looks.
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Old 01-28-2008, 02:32 AM
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Yeah, I'd buy one in a heartbeat! (and give me a good reason to go to the railroad museum!)
I've gotta say that is a great shot of the rear of your rig. (second set #3) I want mine to look cool like that! It's my current desktop!
Harry
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Last edited by HorribleHarry : 01-28-2008 at 02:45 AM.
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  #7  
Old 01-28-2008, 06:17 AM
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Looks good. I have two little girls also. Same thing, my little Jeep just wont fit everybody safely.

A little offline here....Why are your shocks bottomed out? does that set up weigh 2500lbs?
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  #8  
Old 01-28-2008, 09:23 AM
FSJ Guy FSJ Guy is offline
 
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You still have a lot of weight on those rear bumper mounts. Might want to weld them to the rear crossmember if you haven't already.
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Old 01-28-2008, 11:39 AM
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Could you post a pic of where you cut it from the back of the wheel well to the bumper for the slider? That's exactly what I was wanting to design for my truck, just without the tire carrier.
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Old 01-28-2008, 02:29 PM
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bumper looks killer great job!!!!!
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Old 01-28-2008, 08:10 PM
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nice work looks good
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  #12  
Old 01-29-2008, 10:32 AM
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Here are some more pics of the bumper, the wheel wells that I cut out, ect...

Also for those that were curious if I caould make some more, I am sorry but at this time I can't. I live in Sac, but I built the bumper at my Uncle's house down in Napa. I work 40-50 hours a week and I am also an Air Force reservist, so that takes up at least 1 weekend a month. I started talking about buying a winch and making a front bumper and lets just say my wife didn't give me the look of approval. If my next project doesn't involve hardwood flooring, then I may be sleeping in the old waggon. At least the back seat folds up.
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File Type: jpg 013 Resize30.jpg (75.1 KB, 201 views)
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Old 01-29-2008, 11:39 AM
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Very nice work!

I got rid of the J-10 project for the Chief after our first daughter was born. Now that we have two, I'm very glad I did.

You should have pic #5 2nd set as your avatar.
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Old 01-29-2008, 12:13 PM
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sac_waggon sac_waggon is offline
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Quote:
Originally Posted by Casey


Very nice work!

I got rid of the J-10 project for the Chief after our first daughter was born. Now that we have two, I'm very glad I did.

You should have pic #5 2nd set as your avatar.

Done!
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Old 01-29-2008, 01:11 PM
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Nice job, looks clean.
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Old 01-29-2008, 06:17 PM
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Great bumper job, I'm inspired. Thanks for the picks. One question, how does the latch on the swing away rack work? Thanks again.
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  #17  
Old 01-30-2008, 10:44 AM
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Great write up,thank you. That there is some kinda Fab skills!!!
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Old 01-30-2008, 12:45 PM
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Quote:
Originally Posted by HorribleHarry
Yeah, I'd buy one in a heartbeat! (and give me a good reason to go to the railroad museum!)
I've gotta say that is a great shot of the rear of your rig. (second set #3) I want mine to look cool like that! It's my current desktop!
Harry

Here is a production version of his bumper:

http://www.bjsoffroad.com/cartgenie/...pid=500&cid=20

Thanks.
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Old 01-30-2008, 01:02 PM
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We have a vendor section
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Old 01-30-2008, 02:15 PM
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TPICherokee TPICherokee is offline
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Quote:
Originally Posted by tkiller13

We have a vendor section

And your point? A person said they would buy something in a heartbeat if it was available, I was showing that it was available, some people don't check the vendor sections....
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