YJ Bumper Build

[BC Explorer]

Well I finally started on build a rear bumper for the YJ with clevis mounts and reciever.

The Bumper started as a peice of 2x4x3/16 and will sit flush against the Jeep rear crossmember. I milled bolt holes on the back side were a nut strip will be welded in side the bumper before putting on the end caps.
I also milled three 3/4" holes so that I could plug weld the back side of the clevis mount to the back of the 2x4. Clevis mounts are 3/4" stock and should be strong enough.
Here are some pics so far and I post more when I get back from the shop today, hopefully I can fit it on the Jeep today.

This makes it so much easier when doing projects.
http://i96.photobucket.com/albums/l171/yuchym/C071808_1916_01.jpg

http://i96.photobucket.com/albums/l171/yuchym/C071808_1917_01.jpg

http://i96.photobucket.com/albums/l171/yuchym/C071808_1930_00.jpg

[StumpXJ]

I love my Mill and Lathe for projects on my truck. Its not exactly the Bridgeport you have, but it works! Nice start on the bumper!

~James

[BC Explorer]

Well I did some more on the bumper and now have it on the YJ and only need to start on the tire/jerry can carrier.

Clevis mounts are finished and welded in.
http://i96.photobucket.com/albums/l171/yuchym/C071908_1217_00.jpg
http://i96.photobucket.com/albums/l171/yuchym/C071908_1233_00.jpg

And because I'm bolting the bumper directly to the rear crossmember I had to create a nut strip and weld it inside the bumper.
http://i96.photobucket.com/albums/l171/yuchym/C071908_1202_00.jpg
http://i96.photobucket.com/albums/l171/yuchym/C071908_1341_00.jpg

I then machined a spot on the bumper to locate the swing arm pin. There are 2 holes because I change my mind after I drilled the hole on the right. OOOPS
Any ways I weld it back and now no hole.
http://i96.photobucket.com/albums/l171/yuchym/C071908_1701_00.jpg
http://i96.photobucket.com/albums/l171/yuchym/C071908_1700_00.jpg

The end caps are finished and bumper mounted, I'll post pictures later today.

[StumpXJ]

Are you going to just spray paint it or? The last bumper I did for a friend, I accidentally put the seam to the outside like yours is. It didnt look so hot after I painted it, but a coating like Rhino lining or something will cover it nicely. I know its too late to turn back now, I learned the hard way also. Looks really killer man, and a heck of a lot cheaper than something prefabbed!

~James

[BC Explorer]

Truck bed liner is my best friend, I sprayed my rack with it as well and if it gets all scratch and looking crappy you just respray it.
It also helps that a buddy of mine works at Line-x.
I know what you mean about thew seam, on this bumper I wasn't worried.
I just built another bumper for a customer and it has the seem facing inwards because it is just being painted.

[StumpXJ]

Yeah, bedliner makes my welds look like a champ! I see you dont have that problem, but it works for me.

~James

[BC Explorer]

Well here are some more updates on the YJ bumper build.

This how the hinge goes together, but right now without the cap bolt
http://i96.photobucket.com/albums/l171/yuchym/DSCF3159.jpg

One big issue I had to deal with was how to mount my jerry cans.
I was going to use the Blitz mounting system but, they look bulky and don't hold the plastic cans so well so I came up with this.
There will be a strap that holds the jerry can in place.
http://i96.photobucket.com/albums/l171/yuchym/DSCF3161.jpg
http://i96.photobucket.com/albums/l171/yuchym/DSCF3166.jpg

And with the first jerry can in place.
http://i96.photobucket.com/albums/l171/yuchym/DSCF3163.jpg
http://i96.photobucket.com/albums/l171/yuchym/DSCF3162.jpg