Another XJ front bumper build
05-01-2013, 07:07 PM
#1
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Year: 1997
Model: Cherokee
Engine: 4.0 HO
Another XJ front bumper build
I know there is nothing but endless front bumper builds here but figured why not. Maybe someone attempting this for their first time can learn something.
The run down.... material chosen for front and angled sides is 2×6, 3/16 wall. Pulled mangled front bumper off, measured bumper bolt locations and the three bolt holes past them. Measured distance between bumper brackets.
Fired the water jet up, cut two brackets from 3/8 plate CRS. Brackets use three existing bumper bracket holes and the three holes just beyond those. Fired marvel CNC saw up and cut the three main pieces of 2×6 and the angles needs to meet my measurements.
Threw a piece of 3/16 plate CRS on the shear, cut a piece 25×6, threw it in the brake press and formed a 45° on each end for the center winch plate.
Welded all that up on the miller 2 phase 220, .045 wire. I also cut two pieces of 3/16 to cap the rest of the top, and end caps that will cap the end to make it look like it wraps around two inches. The angled ends will be cut and capped where you see the sharpie lines. That will be welded up tomorrow.
Enough talking, on with the pics.
More to come tomorrow. Trying to get all of it done before Monday so I can drop the finished bumper off at the powdercoaters while the jeep is at the body shop all next week.
The run down.... material chosen for front and angled sides is 2×6, 3/16 wall. Pulled mangled front bumper off, measured bumper bolt locations and the three bolt holes past them. Measured distance between bumper brackets.
Fired the water jet up, cut two brackets from 3/8 plate CRS. Brackets use three existing bumper bracket holes and the three holes just beyond those. Fired marvel CNC saw up and cut the three main pieces of 2×6 and the angles needs to meet my measurements.
Threw a piece of 3/16 plate CRS on the shear, cut a piece 25×6, threw it in the brake press and formed a 45° on each end for the center winch plate.
Welded all that up on the miller 2 phase 220, .045 wire. I also cut two pieces of 3/16 to cap the rest of the top, and end caps that will cap the end to make it look like it wraps around two inches. The angled ends will be cut and capped where you see the sharpie lines. That will be welded up tomorrow.
Enough talking, on with the pics.
More to come tomorrow. Trying to get all of it done before Monday so I can drop the finished bumper off at the powdercoaters while the jeep is at the body shop all next week.
05-01-2013, 08:41 PM
#3
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Year: 1997
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That is the plan. Clean and strong. It will look much better tomorrow when I cut both ends at an angle and put shackle mounts on. Then off to powder coating.
05-01-2013, 09:18 PM
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Year: 1997
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You can see from the damage to my front end that the stock bumper did not hold up too well. That was a 55mph smack to the concrete center divider on the expressway. The only damage was the front corner you see, and the airbag deployed. No mechanical damage what so ever. I had plans to build front and rear bumpers but that accident motivated me a little.
05-08-2013, 12:39 PM
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Year: 1997
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Well here we go. Got the sides angled, capped, top plates cut and working on the shackle mounts now. Top plate is 11ga, shackle mounts are 3/4 thick, 6 inches long to go all the way through the bumper and weld onto the sides of bumper brackets.
Prepped for welding
Prepped for welding
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05-09-2013, 11:27 PM
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Year: 1997
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I'm having it powder coated satin black. Still have to cap the ends and put shackle mounts on. I have been going back and forth on if I want to bend some tubing for a brush guard or not. Idk. I think I will bend some up, set it on and see how it looks.
05-12-2013, 08:06 PM
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Year: 1987
Model: Cherokee
Engine: 4.0L straight six
so I just took off my front bumper and I was curious did you trim that metal right in front of the fender and the fender as well to get that bumper to go on? I see this as a big issue for some issue