Another XJ front bumper build
CF Veteran
Joined: Aug 2011
Posts: 1,994
Likes: 8
From: San Jose
Year: 89
Model: Cherokee
Engine: 4.0 I6
I cut a big L out of cardboard, remover the bumper and held a leg of it flat under the front clip, while I used a thin sharpie to lay a flat line along the fender. Cut out everything below that line 
my bumper had mounts that went around the weird triangle thing so I left that there, but there was a little bolt tab that I cut off if I recall.
Stupid phone, ignore that picture haha
my bumper had mounts that went around the weird triangle thing so I left that there, but there was a little bolt tab that I cut off if I recall.Stupid phone, ignore that picture haha
Thread Starter
Junior Member
Joined: Apr 2013
Posts: 86
Likes: 0
From: Portage, IN
Year: 1997
Model: Cherokee
Engine: 4.0 HO
Work has been hectic so this has been slower than I thought it would be.....but it is done and just dropped off at powdercoaters. Once back from them its time to bolt the winch to it and throw it on for the last time!
Thread Starter
Junior Member
Joined: Apr 2013
Posts: 86
Likes: 0
From: Portage, IN
Year: 1997
Model: Cherokee
Engine: 4.0 HO
That was the plan. I need my winch to be recessed into the grille. That was the plan from the beginning. I hate the look of a bumper sticking out too far. I went the absolute minimum with still being able to fit my winch, a warn XD9000i.
Seasoned Member
Joined: Feb 2010
Posts: 262
Likes: 1
From: Montana
Year: 2000
Model: Cherokee
Engine: 4.0
Put a receiver in that bumper, then put winch on a plate with receiver tube. That way you can use it front or back, and when not in use it's out of the elements. I love mine thats set up that way
Senior Member
Joined: Aug 2009
Posts: 838
Likes: 0
From: Tulsa,Oklahoma
Year: 97
Model: Cherokee
Engine: 4.0
you obviously have the skills and most importantly access to some killer equipment, I'd seriously consider building/selling these to fund some of that equipment
I'll buy one without the bar..
btw, I need some water jetting if you price that out pm me...
I'll buy one without the bar..
btw, I need some water jetting if you price that out pm me...
Newbie
Joined: Dec 2012
Posts: 9
Likes: 0
Model: Cherokee
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.
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