My front winch bumper fabrication

[oderdene]

Decided to fabricate front winch bumper...

mine was:

http://i861.photobucket.com/albums/ab180/od_999/my%20xj/Photo-0149.jpg


removed front bumper and bull bar:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/frontremoved.jpg


bought 5mm sheet metal:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/sheetmetal.jpg


prepared support template using tow hook bracket:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/template1.jpg

[oderdene]

supports cut:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/support.jpg

winch plate and rear crossmember:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/rearntopmiddle1.jpg


fitting:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/testfit1.jpg

and angle bracket for passenger side:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/anglebracket.jpg


fitting passenger side support:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/testfitright.jpg


both:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/testfit3.jpg


ready for welding:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/rearntopmiddleforwelding.jpg

[oderdene]

front cut:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/fendercutleft.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/fendercutright.jpg


template for "wing":

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/template2.jpg


cutting wings:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/wingcutting.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/wingleft.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/testfitnwings.jpg


support and tow point (for D ring):

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/supportntowpoint.jpg

was 7mm plate and was very hard to cut.

[96xj]

looks good keep up the good work :shocker::thumbsup:
and keep taking :camera::camera: and post as you go

[oderdene]

welding wings:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/wings1.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/wingswelding2.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/wingwelding.jpg


welding more...

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/weldingtops.jpg


backside...

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/weldingtop.jpg


and grinding...

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/grindingtop.jpg





D ring hole drilled - 25mm :

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/towpoint2.jpg

[oderdene]

Test fit:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/testfit2.jpg


Front plate cut & welding:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/frontwelding.jpg


welding again and grinding again...

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/weldingngrinding1.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/finalgrinding1.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/afterweldingbottom.jpg


and undercoated...

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/prime.jpg

already dark :D

[oderdene]

Painted and installed:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/paintedtop.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/paintedbottom.jpg


... closer look:

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/closer.jpg

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/installed.jpg

[oderdene]

Tools used:

- Angle grinder
- AC Stick welder (chinese, BX6-300 said 300A)
- Electric hand drill
- 2.5HP Air compressor
- wire brush (hand and for angle grinder)

and Canon Powershot A710 IS and of course some beer :)

[Mudderoy]

It's like reading a good book. Once you start you don't want to stop. Thanks for all the pictures. When's the winch going on? If I'm lucky I'll get one some time next year. :sad0147:

If you haven't already done so, I would drill a hole in the middle of the winch tray so the water can drain out.

[oderdene]

Warn; Mile Marker etc US made winches are very expensive and rare here. I read something about chinese/taiwanese; 9500lbs is around 350$. but still in doubt

[oderdene]

Sure, winch plate is 20cm x 60cm. As my reading, most winch mount holes same pattern - 254mm x 114.3mm. Is it correct? What about position? Center or some offset (left/right)?

[Mudderoy]

Sure, winch plate is 20cm x 60cm. As my reading, most winch mount holes same pattern - 254mm x 114.3mm. Is it correct? What about position? Center or some offset (left/right)?

Mine was made with slots. Adjustment forward and backwards. I'll have to take a picture and post it, but I think it is centered.

[96xj]

just wait til you get the winch wich one are you looking at i know payless4x has a really good price on smitybelt RC8 for under $300

[96xj]

why would anyone off center it it should be dead center

[alwaysxj]

looks good. i was unsure of how it would turn out with the first pics but it turned out nice. what kind of wheeling do you do over their? rocks,mudd or what?

[xj4life2]

Nice job !! turned out well.

[oderdene]

looks good. i was unsure of how it would turn out with the first pics but it turned out nice. what kind of wheeling do you do over their? rocks,mudd or what?
This is my daily driver, I want to build good looking XJ with some offroad capability. No extreme rock crawling and deep mudding.

[BlueXJ]

Looks strong.

[oderdene]

dear friends,

give me a light bar or other fog light mounting idea on my bumper.

PS: will start rear bumper this weekend.

... and roof rack ... and rocker guard ...and rear tire carrier ...and snorkel ...and more :smiley-gen165:

want to participate expedition to countryside during winter. :stars:

[Mudderoy]

Well your bumper looks similar to mine, so here is mine with a single hoop.

http://xjtalk.com/images/special/bumper30.jpg

I wanted the hoop for some winch projection and lights.

[oderdene]

This is my daily driver, I want to build good looking XJ with some offroad capability. No extreme rock crawling and deep mudding.

want to build expedition car like this one (http://farm4.static.flickr.com/3549/3374143714_9b6bde5490.jpg), but will not chop rear. :driving::driving::driving:

http://farm4.static.flickr.com/3549/3374143714_9b6bde5490.jpg

[jugbutt]

Man that is alsome

[Mudderoy]

Need more pics and info. The thead got real interesting and just died! :rotfl2:

[Melissa]

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/installed.jpg

Very nice, I like http://i730.photobucket.com/albums/ww305/melreese83/smilies/party0009.gifhttp://i730.photobucket.com/albums/ww305/melreese83/smilies/jumping0051.gif

[4.3LXJ]

If you are wanting to mount lights, you might want to consider a roof mount instead of bumper mount. It is up to you of course. The advantage of roof mount is the there is an increase in downward angle of the light, making a larger shadow behind bumps and holes so they are easier to see.

Also on the winch mounting. The footprint is almost universal now. They are almost all the same. The only problem is the length of the electric motor in a depressed mounting like you have. Many of the winch companies are using identical gear sets and casings, which I believe come from China. The only real difference is the motor.

[Mudderoy]

When Spanky was making my bumper "depressed winch mount" he asked for the specific winch I was going to buy. If I ever see any extra money again, I'm getting the Superwinch epi9.0.

[BlueXJ]

Any update on the rest of the things you were going to build for your Jeep???

[COSXJFAN]

Nice job!! To me, anyone can bolt on a bumper from a box, but when you make something yourself, it gives a tremendous feeling of pride. I like the fact that when people ask me where I bought my bumper, I can reply, I didn't, I built it!! Half of the time they ask, well can you build me one, and I say no dice!! LOL!! I would love to be able to get into that business, but right now it;'s not in the cards!! Again, nice job man, you have something to be proud of there!!

[96xj]

it looks bad :moon:
you wanna build me one too :scared0016:

[COSXJFAN]

The proper response is...NO DICE!! LOL!!!:shocker:

[DETOURS]

This is where the fun of the "Custom" relationship between you and some customers come in........as a fabricator, you take on the challanges of what another mind is picturing, and attempt to meet 'their' mindset.........to that I say "Dice? Well hell yes.........Whats on your mind?"

It's not easy, but, it can be fun for a change of pace.......and when people mesh well during a project, you can become pretty good friends.

Ya gotta always remember.......Not everyone has mad-fab skills, not everyone has the time to learn how to weld, not everyone has resources, and quiet frankly.....not everyone wants to learn how along with all the black boogers that go along with doing so.

[COSXJFAN]

Black boogers....UHHGGG!! Yep, I know all about those!! That is kinda my problem too. I do not have any of the equipment, but I do have "some" skills. I'm in a weird spot in this little game!! LOL!! I have a freind with all of the nice tools, and he will let me use them, but it will be way better whaen I can afford MY own equipment!!

[DETOURS]

I hear you, I started buying 1 pcs at a time......while running someone elses business (employed in other words)......over time, I've been able to create the shop.

[BlueXJ]

NO http://i216.photobucket.com/albums/cc169/megan_dustergirl74/fuzzydice.jpg

[COSXJFAN]

C'mon 7...C'MON...Damn.....snake eyes!!:eek:

[DETOURS]

Ha Haa!! :rotfl2:

[GoreXJ95]

Could you give me the demisions for all the peices that is now gonna be my new project

[oderdene]

Thanks all of you my friends,

i just come back from countryside mission, my job is a regular maintenance of equipments installed at remote sites and training of officers. over 3500 km of travel. Best part of this journey was road between Khatgal and Khankh; 180 km took 11 hours - mountain, snow, mud, river etc.

PS: our company hired 2 LandCruiser 105s and 1 LandCruiser 80s for this journey.

Will be there next June with my XJ. :driving:

[oderdene]

sorry, i don't have dimensions on my hand. will measure tomorrow for you.

i did it on the fly, using cardboard and dimensions not noted.

[DETOURS]

Thanks all of you my friends,

i just come back from countryside mission, my job is a regular maintenance of equipments installed at remote sites and training of officers. over 3500 km of travel. Best part of this journey was road between Khatgal and Khankh; 180 km took 11 hours - mountain, snow, mud, river etc.

PS: our company hired 2 LandCruiser 105s and 1 LandCruiser 80s for this journey.

Will be there next June with my XJ. :driving:

I want YOUR job. :thumbsup:

[oderdene]

Could you give me the demisions for all the peices that is now gonna be my new project

i prepared drawing here and measurement is rough and metric (0.18 means 18 centimeter). Please don't strictly follow these dimensions, angle grinder is a great tool for correcting my errors.

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/MyBumper.jpg

:stars: measure ten times and cut once :stars:

[oderdene]

Could you give me the demisions for all the peices that is now gonna be my new project

you have to make cut on front plate for support plate

http://i861.photobucket.com/albums/ab180/od_999/xj%20front%20bumper/Indentforsupport.jpg

[Mudderoy]

Very nice drawing. There is two things I would do differently, speaking from years of vast experience designing and building ZERO bumpers. :smiley-laughing021:

I would make the unibody frame tie in out of thicker metal. I would start off with the base being a rectangular tube, all the plates would hang off of it. That gives the bumper a strong base and a strong tie into the unibody.

Just my 2 cents.

Those two things would give it much better lateral strength. I think that the first side pull from your winch will shift the bumper in the direction of the pull.

[N1TZU]

Very nice oderdene,Awesome fabrication job you did there...Cool stuff to see someone make there own jeep mods.....

[4.3LXJ]

:thumbsup:Very neatly done so far. Keep going....

[oderdene]

After long travel and due to cold winter weather, almost finished my front bumper.

http://i861.photobucket.com/albums/ab180/od_999/my%20xj/IMG_3031-1.jpg

want to order rectangular fog light and WINCH...

and did my temporary rear bumper
http://i861.photobucket.com/albums/ab180/od_999/xj%20rear%20bumper/IMG_3038.jpg
http://i861.photobucket.com/albums/ab180/od_999/xj%20rear%20bumper/IMG_3043.jpg
:)
next spring will finish it - will add tire carrier, redesign both end.

[oderdene]

another end of rear bumper
http://i861.photobucket.com/albums/ab180/od_999/xj%20rear%20bumper/IMG_3036.jpg

[oderdene]

one more ...

http://i861.photobucket.com/albums/ab180/od_999/xj%20rear%20bumper/IMG_3042.jpg

[Mudderoy]

Why just one more? Are you teasing us, or think you are posting to many pictures? If it's the latter then keep them coming! :rotfl2:

If it's the first one, then STOP IT YOU BIG TEASE!

[oderdene]

:confused: sorry for that :confused:

[AZXJ]

Great job! I like all the pics. The bumper came out nice.

[rguignard]

one more ...

http://i861.photobucket.com/albums/ab180/od_999/xj%20rear%20bumper/IMG_3042.jpg

what is the hitch thing on the rear bumper and what do you use it for ? i havent seen one of them before. i like the frt bumper im in the building stage of both of my bumpers right now .

[oderdene]

yes, this is tow bar fully welded and bolted to uniframe. Seems old european style :D I welded bumper on it.

[rguignard]

is it a ball for towing or ????

[oderdene]

this is a photo from bottom,

http://i861.photobucket.com/albums/ab180/od_999/xj%20rear%20bumper/IMG_3060.jpg

nothing to tow, it is noa REAR SAFETY KIT :D

[rguignard]

i fell sorry for what ever hits it :shocker:you win on both sides i cant wait to see them done :thumbsup:

[oderdene]

Today I bought Warn XD 9000 12V at 165$, almost not used. dismounted myself from imported Toyota LC 80. :D :D :D

http://i861.photobucket.com/albums/ab180/od_999/my%20xj/winch/IMG_4350.jpg

http://i861.photobucket.com/albums/ab180/od_999/my%20xj/winch/IMG_4351.jpg

http://i861.photobucket.com/albums/ab180/od_999/my%20xj/winch/winchxd9000.jpg

thinks very good deal and will install soon.

too many wills, not enough time :(

[oderdene]

No remote control; wants to install solenoid box under the hood and add switch on dash.

[rockcrusher]

Hows it going with the winch install?

[oderdene]

No progress at all. Very busy here and will try to find 2-3 free days by end of May and dedicate those days to my XJ.

gimme a time please, a want to make happy my pretty...











.... XJ