Mtbxj87's 1989 XJ

[mtbxj87]

I started on the rear bumper and tire carrier. I focused on light weight. There is a million ways to do this. I'm keeping it simple and light. I started by making but strips/ frame inserts with 2" .25" angle. Welded my nuts on top of that.



Made my plates for the 4bolts 3/16"

Bolted the brackets up and took some measurements. Drew some pictures on my .120" 2x4. Then cut it out


Test fit with the angle


Test fit on the truck.
I ****ed up my original plan. I cut my angle too short. I wanted the bumper further out and still have some angle past the 2x4. It's ok thought cause the swing out will mount to the back of the 2x4 and stick out a few inches, keeping it tight but not too tight.

Notched out the .25 angle to add Clevis tabs, burned those in. Mounted them low cause the swing out will be above.

Notched the 2x4 some more, fitted it and burned it home

 

[mtbxj87]

Flux core sucks. Mostly for clean up.

Here's a side shot. I'll loose the hitch eventually, but it works with my bike rack very well so it stay for now.

Burned it in and made more flux core mess. After welding it completely I boxed in between the plate and the 2x4 with more angle. So it's all completely welded in side and out. It should be plenty strong with the amount of weld surface. I'm going to add a few more tabs on the inside to mount to the body at the ends of the bumper. Cap the ends and put the fActory bumper end caps on for a clean, the way the factory should of done it, look.
More updates to come

 

[Overland History]

Great job on the bumper so far! I really like how you notched the angle into the 2x4 to be able to accept the plate where the stock bumper holes mount. I may have to steal(steel? ) that idea when I redo my rear bumper!

Anxious to see the end results!

 

[mtbxj87]

Thank you, I'm excited. I learned a lot. Ideas are meant to be shared. So far it's about 30 pounds,

 

[mtbxj87]

Added another support bracket from the bumper to a pinch seam. It should tie the "frame", rear panel and quarter panels together nicely. I cut the ends at *45. Not sure why, but I did.
Then I shot some primer and paint. Bolted it on.

Still need to fit the caps back on. Next I'll start the swing out.

 

[XJSuperman]

Looks pretty good.

 

[mtbxj87]

A few updates, still chippin away at it.

Started on the swing out. I'm going to try a poly bushing for the hinge. Here I have it offset, the bar will be high on the pivot and offset close to the bumper.

Burned on my tabs. I'm using Barnes 4x4 trans mount kit. Comes with 2 massive poly bushings and 3/8" tabs.

This is goin to be my latch, simple bolt. It's 7/8" grade 8.

Burned it to a piece of 3/16. I'll cut a hole in the bumper so the nut will recess and I'll weld the plate to the bumper. The swing out beam will have a sleeve where the bolt will go through. I'll figure out a t handle for the bolt

 

[mtbxj87]

I mocked the arm up and made some measurements. Then drilled a 1.25" hole with a hole saw for the nut to recess into.


Like so

Bolted my sleeve in place then test fit and adjusted my notch.
Tacked it then took it off to weld it. I ran out of wire so I'm done for the night.

This is with it closed

 

[mtbxj87]

Got back to the tire swing out.

Cut out my main upright like so. I offset it for more clearance between it and the hatch.


Squared it up and tacked it in place

Then I made this out of left over 1x2

Notched out my upright

Then welded it in place

Notched out a 7" piece of .25 angle
And set it

Support with 45*
.188 wall 1.5 square

 

[mtbxj87]

Burned it all in and used spare wheel studs.

Side view. I'm about 90% done with the swing out. Then on to the right side swing out for fuel cans. And get a 31" spare. That's a 235/75. I made my measurements to fit up to a 33"
I'm stoked on how it came out. Yes the poly bushing sags when it's open but when it's bolted it's solid. I welded a piece of angle so I can lift the swing out on to it and easily thread the bolt in. Maybe some day I'll replace the poly with bronze.

 

[Overland History]

Great work!

 

[mtbxj87]

Thank you. Tomorrow I'll run it down some dirt roads to test it

 

[mtbxj87]

I don't know if these can be seen. They keep changing tapatalk, it real ************* annoying.
My bike rack just fits, I can adjust the bike tray in front back some but I still won't be able to flip the rack up. I'll figure something out

 

[SilicaRich]

Awesome work man!

 

[mtbxj87]

Thank you
I found a 31" spare tire locally and painted the wheel flat black to match my other wheels.

Test drive proved success. No rattles or anything falling off. My "latch" stayed tight