NoobJeeper

I want to make a custom front bumper for my rig and it would be nice to have a set of plans or pics (with dimensions) of the mounting brackets. I am to lazy to take mine off to see what I need.

Thanks, Mike

seer1

PM BLKRUBI, he just finished making his.

VBS4

Well it depends on how detailed you want to be. I've been working on my custom stubby also. I bought a 4 ft section of 6X2 C-chanel.
and cut it into 3 sections.
1. 39" section (front bumper from frame rail to frame rail)
2. (2) 6" sections for each end that angles back at 45 degrees (towards the tires/grill)

I welded it up in my garage and used an angle grinder to finish it off.

I then used black krylon spray on truck liner to coat it with. It gives it a nice textured look.

I've got it on there now. I'm not completely finished yet since I have to source some small sections of 3/16th plate.

I've got some pic.s at home I'll try to post up.


As far as mounting brackets, you really don't need any. There are 4 bolt holes on each frame to bolt the bumper to. (pic.s will help...lol)

BLKRuby

It depends if you want to hide the bolts or have the bolt heads showing through the face. In my opinion it looks cleaner to have the bolt heads hidden behind the face. Let me try drawing it up.

NoobJeeper

and for the crappy crush cans? do I unplug them? will it void my warranty, screw up the computer??

smack2020

crush cans are not hooked up to anything. They are attached to the metal part of the bumper. You will not use them, they are joke.

BLKRuby

I don't have a drwing program, so will do my best to describe how i did it.

First off if your too lazy to take the bumper off and look and measure, i can't imagine you being not lazy enough to do this, but...

1. I took 1x1 square tubing and cut it to the lenth that the heigth of the frame rail (6" off the top of my head). 4 of them.

2. Place cut tube up on the frame mount and mark where the holes will be, on mine the top of the tube was flush to the top of the frame mount.

3. Drill the tubing where you made your marks, go all the way through both sides, with a 1/2" drill bit.

4. Next use a cut off wheel and on one side of the square tubing, cut a square just big enough for a bolt head to enter the channel of the tubing. Note: Only notch the tube deep enough to get the head in, about a 3/16-1/4" Other wise welding will be more difficult.

5.Now you should be able to insert a 1/2" bolt into tubing so that the head sits in the channel and the threads stick out the other side.

6. Construct the shell of your bumper now. Tip: Save the under side of th shell untill later.

7. Take your tubing you just made up and bolt it to your frame rails snuggly.

8. Get your welder ready (disconnect your battery) and a friend would be helpful.

9. Have friend hold the bumper shell up to the tubeing making sure the bumper is centered.

10. Tack weld all the tubing to your bumper (One good tack on each end of tube is good.

11. Take the bumper off of Jeep

12. Now it is time to finish welding the tubeing and shell together. Tip: Use a nut and run it up tight to the tubing on all the bolts, this brings the head of the bolt to the top of the tube and prevents the bolt from being welded on accident too low in the channel. The bolts will be able to move around a little, this is good.

13. Weld all the way along each tube, burnning the mount tubeing and the shell of the bumper in real good. There is a small gap to fill on each tube where you notched, that is why it is important to keep the notch as shallow as possible.

14. Here you may want to clean up the welds so far

15. Finish the shell by welding in your bottom skin. On mine, the bottom only goes back about an 1 1/4"

16. Dependig on what else is planned, your bumper may be ready to go on, get d-rings, winch gurads, winch openings, or some crazy other idea. If you go with d-ring tabs i have a few recommendations.

A. Mount through the face, not just on the face
B Get piece of scrap left over and cut it so it fits between your frame mounts.
C. Cut a hold in your bumer face where you would like the tabs to be (Center of the frame rails is best)
D. With the spare piece you just cut for the backside in place, mark from the front where the tabs go.
E. Cut the hole on the piece that goes in the back, whe layed in the back, you can now see all the way thtough both pieces.
F. Insert the tabs to the depth you would like and weld them to the back support plate.
G. Now weld the tabs on the face as well.
I. Weld the surt plate in the back to the bumper shell, 2 sides are good enough.
J. Now, with good welds, you should have D-ring tabs that could lift the Jeep right off the ground if needed.

Hope this helps, any questions just ask. My bumper can be seen in my gallery.
Maybe someone with a CAD or paint program can try to draw what i just explained a little bit. lol

BLKRuby

The crush cans are not even hooked up to the computer or any sensor. They are unneccesary.

smack2020

here is mine

smack2020

now I am thinking about a back bumper