RPilk's XJ build
 

hey guys, dont plan on a crazy build, but though some of you might enjoy what I am doing.
http://www.ar15.com/media/viewFile.html?i=30864
first was to remove the CRAPPY purple tint from the windows....

Then with the requirement that I needed to be able to tow a trailer, the rear bumper needed to be built.....not bought.:icon_wink:

so removed the stock bumper and cut 2x2 holes in the rear subframe end, oriented to the inside rail.

http://i66.photobucket.com/albums/h2...bumperhole.jpg

made the inserts to support the bumper out of 2x2-3/16 square stock, welded to 1/4" plate...
http://i66.photobucket.com/albums/h2...umpermount.jpg

http://i66.photobucket.com/albums/h2...sertlength.jpg
http://i66.photobucket.com/albums/h2...ountwelded.jpg

there are also bolts that go into the subframe and these tube inserts, you will see them later...didnt get pics of them at this time.....
Now time to work on the bumper.
Started with a 4x6-1/4" tube.......
http://i66.photobucket.com/albums/h2...bumpertube.jpg

marked it for the hitch tube....I bought the reciever tube from the local farm supply..... http://i66.photobucket.com/albums/h2...hholestart.jpg

drilled a starter hole, then cut with a torch on both sides.
http://i66.photobucket.com/albums/h2...tchholecut.jpg
insert the reciever and made sure it is square....
http://i66.photobucket.com/albums/h2...itchinsert.jpg
http://i66.photobucket.com/albums/h2...itchsquare.jpg

Then the welding...
http://i66.photobucket.com/albums/h2...itchwelder.jpg
http://i66.photobucket.com/albums/h2...elderrpilk.jpg

after the hitch is the pull points.....my Buddy Tater266 came up with a great idea.... 3 point hitch points, they are super strong with a swivel ball.... less stress on the pull point and the d-ring.
http://i66.photobucket.com/albums/h2...lpointprep.jpg
then cut...
http://i66.photobucket.com/albums/h2...rpullpoint.jpg
http://i66.photobucket.com/albums/h2...llpointcut.jpg

Mock up...make sure they are right before welding....
http://i66.photobucket.com/albums/h2...lpointmock.jpg

then clean it up and weld....
http://i66.photobucket.com/albums/h2...lpointhole.jpg

http://i66.photobucket.com/albums/h2...tfirstpass.jpg

http://i66.photobucket.com/albums/h2...spullpoint.jpg

then comes the fitting and tacking to the mounts.....
http://i66.photobucket.com/albums/h2...j/20lineup.jpg

pull it all back off and weld the mounts solid.....

http://i66.photobucket.com/albums/h2...xj/21mount.jpg

http://i66.photobucket.com/albums/h2...22mountsup.jpg

and somewhere in there we cut the hitch down and cleaned up the cut....
http://i66.photobucket.com/albums/h2...cutcleanup.jpg

http://i66.photobucket.com/albums/h2...22mountsup.jpg

Then cuttung the ends and cleaning them up.....

http://i66.photobucket.com/albums/h2...utcleanup2.jpg


http://i66.photobucket.com/albums/h2...anddressed.jpg

weld the endcaps,,,,,

http://i66.photobucket.com/albums/h2...nglecapson.jpg

primer.....

http://i66.photobucket.com/albums/h2.../28priming.jpg

then paint....Krylon Khaki.

http://i66.photobucket.com/albums/h2...hakiKrylon.jpg

mount it up to the Jeep......
http://i66.photobucket.com/albums/h2.../31topview.jpg

http://i66.photobucket.com/albums/h2...donefornow.jpg

http://i66.photobucket.com/albums/h2...2installed.jpg

Well guys, hope you enjoyed the first installment.....this will be a very slow build, but hopefully it is done right...... thats the plan.

RPilk

Nice fab work on the bumper. Keep up the good work. Looking forward to seeing your rig develop.:thumbup1:

The end result was well worth the long hours and all the cut once mesure twice. :tongue_smilie:Guess I'm gonna have to start my build thread now! :wallbash:
Watch for the "Zombie Hunter"!!!!:2guns::popcorn:

Hey my Best Friend:thumbup1:..... get to it..... wish we had taken as many pics during our build up of the Zombie Hunter.....:sad: