Started this yesterday, gotta have it done by tomorrow.

OE bumper:
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/3b189f09.jpg

Inspiration from other guys: (credit due where necessary)
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/295506d3.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/aa92474c.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/f69f7b07.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/0ae87898.jpg

Let the carnage begin:
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/d5055a4d.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/19b5f273.jpg

Frame plates are 1/4" and I alternated between 7/16" and 1/2" grade 8 hardware.

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/b8ea13c9.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/53f77358.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/c305523c.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/2fc3d78e.jpg

Trimmed the frame plates to accept D-rings/clevises, and for a decent approach angle.
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/0611c9ea.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/9bfb5634.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/b910172a.jpg

Sandwhiching the 1/4" frame plates between 3/8" "D-ring plates". I tied the D-ring plates into the last two grade 8 bolts on the inside piece, and the outside D-ring plates go back at least another inch or more for strength.

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/c491d790.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/2395d9dd.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/960edab9.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/53897cf8.jpg

Made the front face of the bumper out of a single piece of 3/16"x5" plate, bent at areas to follow the natural curves of the grille. Slotted the front face to slide over the D-ring plates/frame plates.

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/3e0e6feb.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/1a57c603.jpg

Few areas to fill in with weld but it's getting there.

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/bbc565ed.jpg

Cut a piece of ERW tube at a 45* angle on the 3" face of the bumper to add corner support. Ties into the 1/4" frame plate.

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/a6c6f399.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/33786985.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/043dbab1.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/dde14d96.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/ffb3067b.jpg

Starting on the top of the bumper. This is somewhat shitty to do and has been the most PITA. The top is 3/16" diamond plate, 4" wide that we bent the last 1" at a 45* angle to make for a nice curve/transition from the top of the bumper to the front face.

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/82673a3a.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/2e4ac5e1.jpg

Shop dog. Eats sparks that fly so we have to be careful lol. Really cool rottweiler.
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/aade7064.jpg

More to come. Everything is made from either 1/4" or 3/16".

Still need to finish the top, finish the bottom plating that angles back towards the OE sheetmetal crossmember. Also have to drill for the D-rings, add a non-structural stinger (mostly for looks and wrapping tow straps around it when not in use). Gotta cut spines for the back side of the bumper. This will be a bumper meant for a removable winch, that will bolt onto the front much like the red one I used for inspiration above.

Stay tuned.

Forgot to add, the bottom of the bumper is made from more plate that is angled way back. I'll take more pictures of it tomorrow to show ya. It's a pretty sick approach angle. :smokin:

Anyone have good lighting ideas? I want to add lights into the bumper itself - so nothing bolted to it. Round lights on a square jeep doesn't fly too well either.

200+ views and just me so far eh? Tough crowd. :mr-t:

Anywho, didn't finish but got to the "almost there" stage. Ran into issues with breaking off the old bolts in the steering gear box and had to remove the gear box to extract broken bolts. :mad3:

Back to progressssssssssssssss. Started the day out with corners and more corners.
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/77f54f6c.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/f29fc281.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/1abc3143.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/b0846aad.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/57f104bd.jpg

Then, since the steering gear box was removed and all the fluid drained, I decided to get creative and mess with the P/S pump. For some reason, my XJ turns 33's like it's trying to turn 38's. Steering is slow and requires a lot of effort and when compared to my buddy's XJ on 35's with lockers f/r, my open/open XJ with 33's is lacking.

So, I played around with the West Tex mod to increase P/S pump volume. Enlarged the hole out to 9/64" which moved the hole up 1/64" in size (I believe factory was 1/8"). I haven't started the Jeep yet to know if this did anything but it's worked in the past on other vehicles I putz with.

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/ceacf1ec.jpg

Back to the bumper. Skip welding and finish welding to prevent warpage.
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/303fb64b.jpg

Added spine supports behind for structural strength in case I ever come down hard onto an obstacle.
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/92125a6b.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/e6852575.jpg

Added bracing where needed:
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/fb0b370c.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/f35b7bf2.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/ad75534c.jpg

And this is where it sits in primer tonight, drying in a warm-ish garage (65 degrees and dry).
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/5d595778.jpg

I wanted to finish tonight but I'll have to get up early tomorrow and finish before I take the XJ on it's 4 hour journey south. I decided against creating an inlet opening for the P/S cooler at this time because I wanted to keep it one solid piece below with no openings. I'm still looking into lighting ideas so shout out if you've got anything. I also x-nayed the stinger idea because it just didn't fit right.

200+ views and just me so far eh? Tough crowd. :mr-t:



Cause your thread isnt hardcore and theres really nothing to say. Its a nice bumper for what it is...clean, nice lines.. but no offense...whoopy doo. Anybody with mediocre cutting and welding skills can make a bumper. You shoulda just posted pics in the bumper build thread we have goin....

Looks well built and plenty stout, but too bulky for my taste. As far as lighting goes, try recessing them behind the bumper with some 4x6, or however big the lights you have are. I think round lights look better when they're recessed, but to each his own.

Looks like a stock bumper made of steel?
How u gonna put a winch on that thing?

can i get a link to this p/s mod??

Looks like a stock bumper made of steel?
How u gonna put a winch on that thing?
Removable. The winch will be permanently mounted to a removable bracket that I can bolt on and unbolt when it's not needed. I'm doing the same style bumper to my Sonoma so I can move the winch from one vehicle to the other.

Here's my inspiration.

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/6d734a45.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/5eec1401.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/1abc892a.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/bfe6def6.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/0d327830.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/55196c21.jpg

Finished project:
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/c654a849.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/aef83632.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/0d19df41.jpg

can i get a link to this p/s mod??
http://westtexasoffroad.homestead.com/powersteering.html

nice work. you need to invest in a plasma cutter. sure makes those cuts a lot easier and cleaner.
and when did the jeep cherokee forum become hard core tech ? :shaking: this post fits right in with everything else on this forum.

looks like ur off to a good start.

and when did the jeep cherokee forum become hard core tech ? :shaking:

Probably a little under four years ago.
http://www.pirate4x4.com/forum/showthread.php?t=582126

looks heavy, did you weigh it?

at least it looks well built, shouldnt have any problems with it. im not a big fan of the diamond plate, but hey its yours not mine.

and do you plan on reinforcing the back where you plan on bolting and un bolting the winch support from? i didnt see any provisions for that.

looks heavy, did you weigh it?

at least it looks well built, shouldnt have any problems with it. im not a big fan of the diamond plate, but hey its yours not mine.

and do you plan on reinforcing the back where you plan on bolting and un bolting the winch support from? i didnt see any provisions for that.
Weight - about 120lbs or so.

I reinforced the back where the winch will bolt to by adding ribbing/spines behind the front face of the bumper. I put the supports offset a little to the inside of where the winch bolts will be.

See?
http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/ad75534c.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/f35b7bf2.jpg

http://i113.photobucket.com/albums/n214/Rinkrat456/Jeeps%20and%20Gilbert/e6852575.jpg