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TJ Front Bumper Fabrication My Home Built Front Bumper

#1 User is offline   JeepNWilly 

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Posted 17 November 2009 - 11:35 PM

Well since I am about 90% finished with my bumper build I decided to add my writeup to JT.

I had the desire to learn from my dad welding and fab work and thought the bumper was a great start. I took CAD classes in High School which helped me in the design of the bumper. I started looking arround the net for ideas before I started the CAD design. Below is the CAD design of what the bumper will eventually looke like.

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Tools used:
  • WELD-PACK 3200HD Lincoln Wire Feed Mig welder.
  • My dad's Band saw
  • Delta Drill Press thanks to Rollbar
  • Reciprocating Saw
  • Grinder
  • Other Misc Tools
Metal:
  • 1/4" rectangular tube
  • 1/4" steel plate
  • 1" steel plate
  • Square tube used for T-Case Drop (I had a second set that was sent by mistake when I bought my Rough Country Lift)
  • 1/4" L beam
The 1/4" rectangular tube was used for the main body of the bumper and the Band Saw came in very handy for the cuts

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I wanted a stubby bumper to help climb rocks in the future so I cut it about 3'-8" and added the angled cut to give it some finish.
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I used the steel plate as the top cover and the top mount point of the bumper also as a winch plate so I needed to cover the entire area. The plate I had did not go all the way to the back to I used the 1/4" L beam I had thanks to Skinner :rof: I cut it in half to make it into 2 steel plates. one of them was used to extend the frame cover you will see in later pictures.
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After setting it up on the Jeep to get the acurate position I tacked weld it and started the weld process of the plate and rectangular tube.
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After I welded the steel plate to the rectangular tube it was time to close the ends as well as grind the welds to give it a smooth finish. I asked my dad for help on how to close the ends and we used parts of the square tube used for T-Case drops. Unfortunately I do not have any pics of it bur we made some cuts and bent the tube to give it the same shape as the bumper ends and hammerd them into each end og the bumper until they were flush. We then proceeded to weld them and filled any gaps then grinded it until it was nice ans smooth and looked like it was part of the bumper. We carfully measured and drilled the mounting holes and continued to grind and sand the steel.
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After this stage we worked on extending the plate using the section I cut of the 1/4" L beam. My dad suggested doing a diagonal cut so both steel plates come together with a V at the junction so we can fill it with weld to give it the best structural strength. After all welding completed we once again used the grinder and sanding disks to gice it a smooth finish.

My dad prior to retiring from work made the D-Ring Tabs for me from 1" steel plate. Drilled 1" holes for heavy D-Rings. Since I hear that the D-Ring tabs should be put thru the the bumper rather than just welding on the front, I decided to as my dad what he would recommend. (Note he has been welding for over 40 years) He told me that it was not necessary to to do a passthru setup. He has a heavy duty arc welder and used it to weld the Tabs in place. He gave each tab a 1/4" bezel so that the weld can start close to the center of the 1" steel Tabs giving it better hold and continued to build out the weld to releave my fears of it not holding even though it only needed half of the weld we did. The reason we used the arc welder was becasue my mig was not rated for 1" this steel.

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I added the bottom mount tabs and prepped it for painting. I used Etching Primer and Duplicolor Bedliner rattle can spray.

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I still need to add the winch and fairlead attachment.
The stinger will be built when I buy a tube bender. I will also add a Steering Box skid.

PS: Next project will be a tire carrier rear bumper. :lol:
Willy
2006 Wrangler X , 2014 JK Unlimited Sport
Keep Calm And Wave On
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#2 User is offline   Rambo 

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Posted 18 November 2009 - 12:20 PM

nice work man, i see a new future for you!!! willy's offroad 4x4 center! put me down for some tube bending when you get it....
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#3 User is offline   floppy 

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Posted 18 November 2009 - 12:32 PM

yeah that looks really nice. I'm jealous of your skills! And I want your bumper!

#4 User is offline   JeepNWilly 

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Posted 19 November 2009 - 04:35 PM

Thanks :rof:
Willy
2006 Wrangler X , 2014 JK Unlimited Sport
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#5 User is offline   Smokey 

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Posted 19 November 2009 - 06:14 PM

Willy you da man with skills. Why the hell do you have to live so far away? I'll keep you in mind when I need some welding done.
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#6 User is offline   floppy 

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Posted 19 November 2009 - 06:27 PM

No seriously, I want your bumper...


Just kidding. But you do live near me.. Maybe you and I should be friends... lol.

#7 User is offline   JeepNWilly 

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Posted 19 November 2009 - 06:42 PM

View PostSmokey, on Nov 19 2009, 06:14 PM, said:

Willy you da man with skills. Why the hell do you have to live so far away? I'll keep you in mind when I need some welding done.

Hmm a little BBQ and I will bring the welder and make it a welding party.

I am looking for the steel tubes for the stinger. I saw a site that Sergio told me about that sell the tube already bent http://www.jeeptubes.com/. I may go that route.

View Postfloppy, on Nov 19 2009, 06:27 PM, said:

No seriously, I want your bumper...


Just kidding. But you do live near me.. Maybe you and I should be friends... lol.

I am south east of the airport. I hear the Zoo monkeys all the time :2thumup:
Willy
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#8 User is offline   Jim B 

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Posted 19 November 2009 - 07:33 PM

Willy, nice work! :2thumup:

For not having a tube bender and messing a few things up... I personally would go the route of the web site you listed. I briefly checked it out and it looks to be pretty trick. Please let us know if you do order from them. I'm interested to know if they will do the custom measure correct. :haha:
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#9 User is offline   Livefree 

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Posted 19 November 2009 - 07:44 PM

I really like the way you wrote this up. It is very informative makes me want to build my own. Keep the write ups coming. I can't wait to see the stinger.
2002 JT X, 35" MTR Kavlar Goodyear tires, Trail Ready 15"x 10" aluminum Beadlock Rims. Ox Lockers both axles, Currie Anti-Rock, Dana 44’s with Chromoly axles , Custom bully up, Warn 9500ti, 4” long arm lift, 1-1/2” body lift, 1” motor mount lift and more. Atlas 2 speed Transfer case, Custom High Steering and Tom Woods Front and rear Drive shafts. Sniper Fab front Bumper, and Jeeperman Rear. T&T Zero HI line front fenders and corner wrap skins with 4" LED tail lights.

#10 User is offline   JeepNWilly 

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Posted 19 November 2009 - 08:29 PM

View PostLivefree, on Nov 19 2009, 07:44 PM, said:

I really like the way you wrote this up. It is very informative makes me want to build my own. Keep the write ups coming. I can't wait to see the stinger.

Thanks, If you have any questios don't hesitate to ask.
Willy
2006 Wrangler X , 2014 JK Unlimited Sport
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#11 User is offline   justdang 

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Posted 29 November 2009 - 08:37 PM

This is just what i have been trying to sort out.
thanks for the ideas!!

#12 User is offline   JeepNWilly 

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Posted 19 July 2011 - 12:11 PM

Well it has been a while since I built the bumper but since then I finally added the stinger.

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All that is left is to add light mounts near the outer edges and I am also thinking of adding a horizontal bar to the stinger just above the winch for 2 extra lights
Willy
2006 Wrangler X , 2014 JK Unlimited Sport
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#13 User is offline   deevee 

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Posted 19 July 2011 - 01:10 PM

Looks amazing!!

#14 User is offline   Kioti 

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Posted 20 July 2011 - 12:05 PM

Nice Work. I build bumpers as a hobby. That is a really nice simple bumper. (the way I like them) Glad to see someone learning a trade and not just buying it out of a catalog.

#15 User is offline   JeepNWilly 

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Posted 20 July 2011 - 12:07 PM

Thanks,
I rather build it than buy it
Willy
2006 Wrangler X , 2014 JK Unlimited Sport
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#16 User is offline   sgt1022 

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Posted 20 July 2011 - 06:19 PM

You make it look soooo easy. I'm in the planning stages for a bumper/air tank. It is much more gratifiying to see something you thought of and built than picking up a catalog and whipping out the plastic.

#17 User is offline   JeepNWilly 

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Posted 20 July 2011 - 07:22 PM

If there is anything I can help you with just let me know
Willy
2006 Wrangler X , 2014 JK Unlimited Sport
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#18 User is offline   BlackHawkTJ 

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Posted 08 November 2011 - 04:15 PM

Wow looks amazing. Do you mind if.I use your bumper write up to build my own?
97 TJ blackhawk
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31" bfg long trail t/a
warn 8k winch
fog lights

#19 User is offline   JeepNWilly 

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Posted 08 November 2011 - 04:19 PM

Sorry but you will violate the copyright law and my bumper fab patent I have.

:rof:

Just kidding. Go right ahead and if you have any questions go ahead and ask.
Willy
2006 Wrangler X , 2014 JK Unlimited Sport
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#20 User is offline   JBYDesign 

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Posted 08 November 2011 - 04:43 PM

looks really nice!... I really like the cable keeper! Now you are really ready to run into / over an import!
'04 TJ 3" BL lift and 2.5" OME with 32" KM2s custom short cab frenched tail lights bedlinered int. shrockworks sliders custom H1 style intake, 20mm motor can consol, blacked out everything!

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