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Old 06-09-2010, 02:33 PM   #1
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Default My DIY overkill bumper build.

Well I started this project by purchasing a 21 ft. section of 2" x 5" x 1/4" tube. I'm not used to working with metal like this and probably could have gotten by with 3/16" wall, but oh well. My original thought was to sandwich the frame mount with the outer bumper sections. Making the frame mount flush with the face of the bumper. Then I would weld my clevis mounts to the frame mounts and notch the tube around the clevis mount. Here's my pile of tube ready for fab.
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My DIY overkill bumper build.-photo0302.jpg  
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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

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Old 06-09-2010, 02:37 PM   #2
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I wanted to trim down the end sections to make them to a 2" x 2" size on the end. I also wanted to go the extra step and keep the nice rounded edges from the mill. So, I pie cut the end sections, then bent the pieces together, and then welded them together.
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My DIY overkill bumper build.-photo0315.jpg   My DIY overkill bumper build.-photo0316.jpg  
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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 02:58 PM   #3
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Now it was time to pick out my mount material. My wife's uncle owns the shop that I've been working in and he told me that I could use any metal stock he had laying around. I started looking around for a piece of 1/4" x 5.5" or 6" flat bar to make my frame mounts out of. I was hoping that 5" would work, but it misses catching the highest or lowest bolts, depending on how you mount it. I couldn't find any 1/4", but did find a section of 3/8" x 6". I know this is kinda overkill, but hey, it's free. So, I had to go and rethink my design. What I came up with was to make the mount one piece from the big oval, sleeved hole all the way out to the tip of the clevis mount. I still sandwiched the mount between the tube but the clevis mount stuck out from in between the tube. I also added one piece of the 3/8" flat to each side of the clevis mount to make it stronger for pulling. The additional pieces were also trimmed smaller than the mount sticking out so there was area to weld it in real good.
Attached Thumbnails
My DIY overkill bumper build.-1_0-3-.jpg   My DIY overkill bumper build.-0_0-3-.jpg   My DIY overkill bumper build.-1_0-2-.jpg   My DIY overkill bumper build.-clevis-mount.jpg   My DIY overkill bumper build.-clevis-mount2.jpg  

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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 03:03 PM   #4
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Here are some shots after the main body was welded, but the additional 3/8" flat has not been added.
Attached Thumbnails
My DIY overkill bumper build.-0_0.jpg   My DIY overkill bumper build.-0_1-2-.jpg   My DIY overkill bumper build.-1_0.jpg   My DIY overkill bumper build.-1_1-2-.jpg  
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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 03:05 PM   #5
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Here's a couple shots while I'm trying to test it out without mounting it.
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My DIY overkill bumper build.-0_1.jpg   My DIY overkill bumper build.-1_1.jpg  
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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 03:08 PM   #6
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Next was to add the 2" x 2" tube that protects the fenders.
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My DIY overkill bumper build.-bumper.jpg   My DIY overkill bumper build.-bumper2.jpg   My DIY overkill bumper build.-bumper4.jpg  
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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 03:10 PM   #7
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Here's some close ups of the fender protection.
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My DIY overkill bumper build.-corner-pic.jpg   My DIY overkill bumper build.-corner-pic2.jpg   My DIY overkill bumper build.-front-coner3.jpg   My DIY overkill bumper build.-front-corner.jpg   My DIY overkill bumper build.-front-corner2.jpg  

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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 03:15 PM   #8
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Now it was time to sand it down, primer, and paint it with aerosol bedliner. Then I got to install it. Found out 2 things. #1 it's an extremely tight fit. # 2 is that 2 of the bolt holes on each side didn't line up to the existing holes in the frame. A little quality time with the air die grinder fixed that on the driver's side. Now I just need to do it to the pass. side.
Attached Thumbnails
My DIY overkill bumper build.-completed-bumper.jpg   My DIY overkill bumper build.-completed-bumper2.jpg   My DIY overkill bumper build.-completed-bumper3.jpg  
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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 03:17 PM   #9
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This makes phase 1 of the build complete. Phase 2 will come when I buy my winch and buy some tube for the front.
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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 03:21 PM   #10
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This looks good, I like it, How much that thing wiegh
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Old 06-09-2010, 03:24 PM   #11
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Thank you. It weighs just a little over 80 lbs. Like the title says, overkill.
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1996 XJ Sport, wrecked and re-built
Rusty's 4.5" front springs, S-10 b-pack in rear
Rough Country long arm upgrade kit and sway bar disconnects
Rusty's shocks
33" x 12.5" x 15" Goodyear Wrangler Duratracs
Homemade front bumper
HP D30 front with 4.10's and a Spartan locker
Ford 8.8 rear with 4.10's and a LSD

My build thread

My bumper build thread
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Old 06-09-2010, 03:36 PM   #12
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Bumper looks good... feel sorry for anyone or anything that ever gets hit by that thing... are you going to build a rear bumper along the same lines??
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Old 06-09-2010, 03:40 PM   #13
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nice
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97 xj 4.5 RC lift kit with rear skyjacker leaf pack magnaflow exhaust cooper discover stt 31x10.50(junk hate them)homemade front tube bumper trimmed fenders
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98 xj sport 6.5 RCX lift kit,bfg mud terrains 33x12.50,15inch cragar soft 8's, yellow top optima
(thats all I could spend on it as of now will be posting build picks soon)
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Old 06-09-2010, 03:49 PM   #14
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That looks great! Good job with tons of overkill
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Old 06-09-2010, 04:07 PM   #15
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Frigging Sick!!!!! Love every bit of it. Great fab!!
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Old 06-09-2010, 04:07 PM
 
 
 
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