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  1. #1
    Join Date
    Mar 2009
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    Black Diamond Foothills, KY.
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    Default Convert a DETOURS BackBone to a Custom Full Bumper



    Don't think I've ever documented this anywhere, BackBone Winch Mounts always had a 2nd purpose, that being a base to build a full bumper from. Everyone's taist differs, this is simply an example of a bumper I designed off the BackBone, it actually has become fairly popular for an unadvertised product.

    Metal of choice........My build utilizes 4"x2"x1/8" wall tube, being box tube, and considering shipping wght, the 1/8" wall tube can take quite a beating if ever beat'in.....reinforcement & an outstanding approach angle are also key.

    The tubes added are aprox. 18" in length cut at 5 degrees, from there each outboard end is radioused, capped and ground. Inboard portions are notched to fit within the BackBone.



    Using another straight tube, clamp it to the BackBone, clamp your new pcs of tube to the temporary tube, align to the body & tack.......by doing this you'll get a perfect, flush fit with the BackBone....



    Fully weld & grind flush, welding will include flat, vertical & overhead welding, your grinding skills will now come into play.......grind to a flush, flat finish.....





    Wrap around........

    To finish the ends, I like to use 3"x2" tube, 70% of it gets hidden, so we can keep the bumper on a diet by using tube 1" smaller......(it all adds up!)

    Wraps are cut 7.5" long......45 degrees on one end, 5 degrees on the other...



    After prepping, again align with a clamped tube.



    I leave gaps between the parts being welded, this is for penitration, I also run a root pass and a cover pass...



    Knowing the joint needs to be ground flush, smooth......I purposely over-weld.



    Grind......blend........and BINGO!



    So at this point, we've come this far.........



    Not bad so far......thanks.

    From here, there are many different possibilities......but this is for a repeat customer who's bought this bumper possibly twice already (cant remember), this is his third XJ build and wants the same bumper again.....soo...........

    Lets bend some tube!

    Using 1.5 tube, the base starts as 50".......



    Bend aprox. 45 degrees.......

    Then, position the base tube for trimming........



    With tube in place against bumper, scribe the tube for your cut, I use a vertical bandsaw but this can be done in many ways........



    Next........prep, position......measure twice, tack into place.....





    Save the welding for later, move on to upper hoop..........

    It's a JD Square being used to bnd the tube, that said the upper tube blank is aprox. 50.5", bent 22' in at 50 degrees........

    To fit the tube to the bumper, I made cheater sleaves years ago, slide the sleeve over the tube, postion the tube, slide the sleeve down to match the pitch, then slide the sleeve up, give yourself your cut line.......



    Slide up and mark...



    Remove & make your cuts......



    Weld after correctly positioning...



    And there ya go...............



    End product in etching primer..........







    Customer wanted a light weight hitch to be added, he'll be using it for a basket for coolers & fishing gear only.






    A full bumper built from a BackBone...........



    Kinda crazy, kinda fun..........



    This was just 1 example, if you ever decide to do one yourself, please share!!

  2. #2
    Join Date
    Jul 2009
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    Punta Gorda, Florida
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    Default Re: Convert a DETOURS BackBone to a Custom Full Bumper

    Nice!!...
    Now what would sumin like this cost?
    You know that look women get when they want sex? Me neither!

  3. #3
    Join Date
    Aug 2009
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    Asheville, NC
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    Default Re: Convert a DETOURS BackBone to a Custom Full Bumper

    Quote Originally Posted by Punisher View Post
    Nice!!...
    Now what would sumin like this cost?
    ^^ +1!!

  4. #4
    Join Date
    Mar 2009
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    Black Diamond Foothills, KY.
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    Default Re: Convert a DETOURS BackBone to a Custom Full Bumper

    The bumper has sold for 565.00 over the years, plus the ride.

  5. #5
    Join Date
    Mar 2009
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    Cheyenne Wyoming
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    Default Re: Convert a DETOURS BackBone to a Custom Full Bumper

    That is one good looking bumper.
    Panda: 98 XJ Limited*4.0L*AW4*NP242J*HP D30*C8.25 *RE/RC 5" lift*33"MTR/Kevlar*MB Predator 15x8*Serious Offroad Front Bumper*Serious Offroad Longarms*Serious Offroad UTK Steering*Ohana Fab Sliders*2 KC Daylighters*
    6 Hellas*Viper 9klb Winch w/Tough Stuff Synthetic Rope*Rage Roofrack*Uniden CB*Detours A-Pillars*

  6. #6
    Join Date
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    Omaha Nebraska
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    Default Re: Convert a DETOURS BackBone to a Custom Full Bumper

    That is frickin awesomeness! I have been looking at the backbone system for about a year now with the idea of building my own bumper. seeing it done just sold me on that! great work. keep it up.
    Keep the rubber side down.
    I didn't build it to satisfy you. I built it to satisfy me.

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