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XJ Rear Bumper & Fuel Tank Skid Build

Old 03-22-2018, 09:05 AM
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Default XJ Rear Bumper & Fuel Tank Skid Build

After hitting my fuel tank on a rock and having to replace it I decided it would be a good time to build a skid for it. I was building the nutstrips to mount the skid to when I figured what the heck, might as well build a bumper while i'm at it. Sorry there is'nt as many pics as I had hoped.
Started out by fabbing up some Frame tie ins. Made sure those fit nicely and began to cut for the bumper. Started out with a pc of 11ga brake formed in 4 spots to get my main profile for the bumper. Waterjet cut 1" steel shackle mts to weld to the frame inserts. Then cut rectangular holes in the bumper to allow the 1" plate to protrude through.


XJ Rear Bumper & Fuel Tank Skid Build-img_20180222_195242780.jpg

Got everything tacked together, did some trimming, and moved on to the sides.

XJ Rear Bumper & Fuel Tank Skid Build-img_20180223_110617167.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180222_222245117.jpg

Then put the receiver tube in


XJ Rear Bumper & Fuel Tank Skid Build-img_20180224_130120065.jpg

Did a little welding and a little grinding

XJ Rear Bumper & Fuel Tank Skid Build-img_20180224_160819344.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180224_160807969.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180224_160814631.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180224_160802080.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180224_160400815.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180224_160351848.jpg

Confirmed nothing got warped during cleanup


XJ Rear Bumper & Fuel Tank Skid Build-img_20180224_161031920.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180224_160826591.jpg

And then began working on the bracing

XJ Rear Bumper & Fuel Tank Skid Build-img_20180224_163230132_top.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180225_124146469.jpg
XJ Rear Bumper & Fuel Tank Skid Build-img_20180224_163057824.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180224_163051610.jpg
XJ Rear Bumper & Fuel Tank Skid Build-img_20180224_163025052.jpg

Some finishing touches and hit with 240 then 320

XJ Rear Bumper & Fuel Tank Skid Build-img_20180225_124301286.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180225_124252500_top.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180225_124155408.jpg

READY FOR SOME PAINT!

XJ Rear Bumper & Fuel Tank Skid Build-img_20180225_164847644.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180225_164902837.jpg
XJ Rear Bumper & Fuel Tank Skid Build-img_20180225_164841142.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180226_181956881.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180225_164919904.jpg

On to the skid! Used 11ga steel again brake formed and welded on the sides with integrated mounts.


XJ Rear Bumper & Fuel Tank Skid Build-img_20180226_202338023.jpg

Test fit before paint

XJ Rear Bumper & Fuel Tank Skid Build-img_20180226_203127964.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180226_203114173.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180226_192945168_top.jpgXJ Rear Bumper & Fuel Tank Skid Build-img_20180226_192932045.jpg

You can have any color you want as long as it's black

XJ Rear Bumper & Fuel Tank Skid Build-img_20180227_073759045.jpg

Finished product, I really like the way everything turned out! Fits great, nice and tight, sleek look. Works for me!

XJ Rear Bumper & Fuel Tank Skid Build-img_20180227_075959090.jpg
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Old 03-22-2018, 09:42 AM
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Both came out awesome!!!
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Old 03-22-2018, 01:23 PM
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Thanks batman! I just picked up a winch so I plan on doing a similar style bumper for the front soon
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Old 03-22-2018, 03:17 PM
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looks good.
What welder you running?
Also, those bumper brackets,, do they slide into the OEM uni-frame? did you cut openings in the rear panel to open up the uni-frame?


Slack
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Old 03-22-2018, 03:40 PM
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wow... beautiful, clean welds and precise machinework.

Nice job man.
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Old 03-22-2018, 05:19 PM
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Also, was your planning free form and cardboard or CAD?
If CAD, what package?


Slack
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Old 03-22-2018, 11:56 PM
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Awesome. Complete awesome way to show off those fab skills. Wish I had access to some of your equipment lol.
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Old 03-23-2018, 12:29 AM
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So i'll send you $150 and my address if you build me a gas tank skid plate lol. Looks great man!
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Old 03-23-2018, 05:06 AM
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Originally Posted by Slackdaddy View Post
looks good.
What welder you running?
Also, those bumper brackets,, do they slide into the OEM uni-frame? did you cut openings in the rear panel to open up the uni-frame?


Slack
Im just running a hobart 190 for pretty much everything except the 1" shackle mts that welds to the In-Frame brackets, used a lincoln 256 for those

Yes the bracketry slides into the frame. The fuel tank skid and the brackets sandwich the frame, also utilized the stock bumper mounting point on the rear plate.

Last edited by shepboyrd; 03-23-2018 at 05:13 AM.
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Old 03-23-2018, 05:10 AM
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Originally Posted by Slackdaddy View Post
Also, was your planning free form and cardboard or CAD?
If CAD, what package?


Slack
I used 2d cad to replicate the body line profile and cut bend templates. A lot of it was cardboard templates though, not the best at solidworks yet haha. I use a software that is integrated into my waterjet console (FlowPath). Very similar to mastercam
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Old 03-23-2018, 08:18 PM
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That is truly some impressive skills there. I am a retired welder and even in my day, that would have still impressed me. Now there will be those wanting you to build them one and expect it to be $300. lol Superb workmanship my friend.

Happy Jeepin'
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Old 03-24-2018, 02:34 PM
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That is excellent work! Have you considered marketing that? Could you build and market those yourself now that you know what is involved in the whole process or would it be too time and cost prohibitive to be able to market them at a reasonable price, not to mention shipping? Definitely more than $300 worth of work. The question is could you sell make and sell them for under $1000?
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Old 03-26-2018, 11:09 AM
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Thanks Guys! I didn't really consider marketing it because the price range for these bumpers is just too hard to beat, and without having it powder coated it would be hard to sell when the competition's product can sell for less and have it coated.
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Old 03-27-2018, 03:19 PM
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You make it look so easy
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Old 03-27-2018, 08:03 PM
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My Son and I used Flowpath at Tech Shop before they closed.
Flowpath was funny about importing drawings,, they encouraged us to do our drawings natively in Flowpath,, problem was Flowpath was not available for home use,, And I do my best design in my slippers and robe.


Slack


Originally Posted by shepboyrd View Post
I used 2d cad to replicate the body line profile and cut bend templates. A lot of it was cardboard templates though, not the best at solidworks yet haha. I use a software that is integrated into my waterjet console (FlowPath). Very similar to mastercam
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