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rstrucks
12-02-2010, 09:26 PM
Stock sucks, what works better? Build or buy? How did you do your rocker cutouts? Materials used?

As always, pictures help.

biggoofy
12-02-2010, 09:41 PM
Ill post up my pictures starting tomorrow when I cut into the rockers. I will be using 2x4 .25 wall for the main and 2x2 .25 wall for the kicker very similiar to the KOR design just pushed out a tad more 1x1 .25 wall to tie into the uni frame after its plated in 3/16 where the 1x1 will tie in 3/16 will then be welded over that to smooth it out and prevent hang ups

as for other protection I have 3/16 rear armor (still need to add backing plates)
http://farm2.static.flickr.com/1047/5111726886_58315e262e_z.jpg
http://farm2.static.flickr.com/1186/5111704546_043668f17e_z.jpg
for belly protection I'm using the IRO belly skid
http://farm5.static.flickr.com/4112/5024063284_814c08ac22_z.jpg

WJJEEPIN
12-03-2010, 01:31 AM
Ill play.

Using Rocky Road Sliders
I know people think the company is butt but their sliders are tits
http://i133.photobucket.com/albums/q51/btwnmak/RRSlider.jpg

ARB Front Bumper
Its fine for what it is. Kinda a Crummy design, need to pull to much with the winch. Hurts approach angle. I plan on going with a tube/plate for light weight.
4" lift 31's
http://i133.photobucket.com/albums/q51/btwnmak/ARB/6-PSGSidAC.jpg


I got the KOR Tcase skid
http://i133.photobucket.com/albums/q51/btwnmak/Misc%20Jeep%20Pix/MALL%20CRAWLIN/IMG_7106.jpg

zj-on-the-rocks
12-03-2010, 02:33 AM
Built a front bumper for a winch out of 2x4 .120 and a pre bent 1/4" sheet to use as the base for the winch. Alot cheaper than buying one! Don't have recent pic of it being complete (capped and D ringed) Maybe tomorrow I'll take one.http://i1197.photobucket.com/albums/aa440/nowyouseeme-/jeepbumper016.jpg?t=1291358967

5.9 ANDY
12-03-2010, 08:59 AM
got any more info on those rear quater panel renforcement?

biggoofy
12-03-2010, 10:39 AM
There isn't really much more to it than you can see. I will be making countoured backing plates that should brace it up very well if i ever really smack them aside from that I will also be using pan head bolts here soon instead of the standard bolts to prevent the heads of them from being sheared off by rocks. I would have liked them to have been 1/4" but they should be fine at 3/16 for the price I paid I couldn't pass it up.

rstrucks
12-03-2010, 11:04 AM
Front bumper

http://i358.photobucket.com/albums/oo22/ryanshand/ZJ%20build%20pics/IMG_1737.jpg

Bumper brackets

http://i358.photobucket.com/albums/oo22/ryanshand/ZJ%20build%20pics/IMG_1760.jpg
__________________

Modified for winch


http://i358.photobucket.com/albums/oo22/ryanshand/ZJ%20build%20pics/IMG_1801.jpg

Fender protection and rocker skids

http://i358.photobucket.com/albums/oo22/ryanshand/ZJ%20build%20pics/IMG_2482.jpg


http://i358.photobucket.com/albums/oo22/ryanshand/ZJ%20build%20pics/IMG_2503.jpg


I used 1/8 and 3/16" plate for the bumpers. For the rockers I used .120 square tube plated with 1/8" on the front surface and a 3/16" wall rub rail that has held up well. It has plenty of scrapes on it but no dents. The fender protection is .120 wall. My gas tank skid and t-case skid are from Rusty's. Everything has held up well so far.....

xj-to-zj
12-03-2010, 12:06 PM
Stock sucks, what works better? Build or buy? How did you do your rocker cutouts? Materials used?

As always, pictures help.

Yes, the stock, plastic bumpers, suck butt. The first thing I did when I got my ZJ was remove them, front and rear. That alone made a lot more room for tire clearence. I looked around on the internet for some real bumpers front and rear. I then realized how expensive they are to buy pre made with all the brackets and everything. So first I went out bought a cheap welder and tube bender and then went the route of buying some 2x4 rectangular steel and tubing and built my own. The steel was around $150 for all of it, I even have some extra to build my sliders. Anyways I've just found it to be a lot cheaper to build your own. In addition of it being cheaper its a lot of fun and rewarding to work on your jeep yourself and make it your own. Thats just my experience.

ajmorell
12-03-2010, 12:18 PM
I don't know what I have for pictures, I will have to look later. Pretty much all of my armor is bolt on stuff though.

Sliders - JCR. Local to me and a great product, no real complaints but don't necessarily think they are anything better than most of what else is out there
T-Case - KOR HD X-Member. It is just okay. It was a bitch to get it to line up right and I bent the hell out of the rear arm on it without much effort. KOR is well aware of the problem (I'm not the only one who's mangled this arm) but as far as I know hasn't changed the design any. Honestly I would not buy this again, I originally had intended to have JCR make me something but I found a good deal on the KOR HD X-Member second hand

squashman702
12-03-2010, 12:38 PM
There isn't really much more to it than you can see. I will be making countoured backing plates that should brace it up very well if i ever really smack them aside from that I will also be using pan head bolts here soon instead of the standard bolts to prevent the heads of them from being sheared off by rocks. I would have liked them to have been 1/2" but they should be fine at 3/16 for the price I paid I couldn't pass it up.

1/2"? Holy extra weight for no reason. If you're having that much trouble wheeling that you need 1/2" on the sides of your jeep, it might be time to retake driver's ed.

AgitatedPancake
12-03-2010, 01:34 PM
Cut out rockers and beginning of boatside
http://agitatedpancake.com/random/jeep/boatsides/DSC04353.jpg

Door sill gone too, I welded the inner (2") tube to the pinch seam for the entire length
http://agitatedpancake.com/random/jeep/boatsides/DSC04354.jpg

http://agitatedpancake.com/random/jeep/boatsides/DSC04355.jpg

Underside (more support to be added):
http://agitatedpancake.com/random/jeep/boatsides/DSC04360.jpg

http://agitatedpancake.com/random/jeep/boatsides/DSC04365.jpg


http://agitatedpancake.com/random/jeep/boatsides/DSC04366.jpg

AgitatedPancake
12-03-2010, 01:41 PM
Rear bumper build


Hacked out the rear sheetmetal bumper and a ton of extra material under the tail lights
http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3494.jpg

Plate beginnings
http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3505.jpg

http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3506.jpg

http://www.agitatedpancake.com/random/jeep/rearbumper/DSCN3531.jpg

http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3535.jpg

http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3541.jpg

http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3545.jpg

http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3556.jpg

And a hitch
http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3547.jpg

http://www.agitatedpancake.com/random/jeep/rearbumper/dscn3566.jpg

rodd88
12-03-2010, 01:42 PM
I took a crash course in welding and fabricating junk and I did my first bumper, its 3/16th if IRC, and it was scrap we had laying around the ranch. Pics now
brackets... they weigh a good 10lbs easy, I'm looking into making it lighter for next time
http://i938.photobucket.com/albums/ad224/roddd88/d2ac7b86.jpg
http://i938.photobucket.com/albums/ad224/roddd88/c57cfff7.jpg
sorry no assembly pics
http://i938.photobucket.com/albums/ad224/roddd88/d56df4d4.jpg
http://i938.photobucket.com/albums/ad224/roddd88/7611616e.jpg
http://i938.photobucket.com/albums/ad224/roddd88/12a29668.jpg
It held the weight of the Jeep well. I've gone back and redone all the welds, since they sucked bad.
http://i938.photobucket.com/albums/ad224/roddd88/e5c99f54.jpg
The plan is to try and figure a way to mount a winch, and add a clevis. Ill more than likely add a BTF clevis mount. I'm open to ideas and comment by all means. I want to look into putting a few holes to reduce the weight a tad.

conedizzle
12-03-2010, 03:10 PM
If you've got the tools, building things yourself is definately the way to go. My bumpers cost about $120 each in steel to build as opposed to the $800 or so that most bumpers cost. Front bumper is made with 5" channel and 3/16" plate. For the rear bumper, the mounts are 2x4, the main part of the bumper is 4x4, and the sides/corners are 5" channel and 3/16" plate. I also cut up my tow hitch and integrated it into the rear bumper. For other armor I've got the Clayton's belly skid and KOR rock sliders.
Pics:
front bumper
http://i98.photobucket.com/albums/l269/conedizzle/ZJ/img1272843062464.jpg
rear bumper
mounts
http://i98.photobucket.com/albums/l269/conedizzle/ZJ/002.jpg
in progress
http://i98.photobucket.com/albums/l269/conedizzle/ZJ/img1276027184338.jpg
tow hitch
http://i98.photobucket.com/albums/l269/conedizzle/ZJ/img1280804245501.jpg
complete
http://i98.photobucket.com/albums/l269/conedizzle/ZJ/Main%20Jambo%202010/DSC00785.jpg
belly skid
http://i98.photobucket.com/albums/l269/conedizzle/ZJ/DSC00739.jpg

FortCollinsZJ
12-03-2010, 03:29 PM
I originally had a pair of tomken bumpers, and was happey with them, not the prettiest, but they were steel. I like being able to ad a tire carrier to the rear bumper, that was important. I eventually sold them, and built my own custom bumpers, then sold them aswell, buecause they were way too heavy. I now have a ultra light rear "bumper" that I was able to lift overhead with one hand. In the end, I am very glad I went with a smaller, tighter, and much lighter bumper. The jeep handles alot better after dropping all that weight.

A couple obvious but sometimes overlooked points:

~High clearance at whatever cost. Cust as much as you are comfortable with, then cut a bit more. In the end you will be happy that you have the added clearance and space.

~Engineered strength> brute strength
We alll know a 2/2 1/4" wall slider will be very hard to bend, but designing a slider or bumper with additional gussets in key points will help ad strength, and allow for thinner material.
Again, the weight decrease is apreciated later

biggoofy
12-05-2010, 12:55 AM
I must say a plasma cutter is the way to go when doing a boat side saved me a few hours at least. What really takes a lot of time is cutting and reshaping the A and C pillars then re-welding them **** that thin *** sheet metal.

first cut was with a sawsall to oper her up and take a look
http://farm6.static.flickr.com/5285/5233579428_b6fb55c5d8_z.jpg

C pillar after being cut and modified
http://farm6.static.flickr.com/5129/5233580508_d9baf6314b_z.jpg

A pillar during cutting and rework
http://farm6.static.flickr.com/5004/5233580442_1932f883a9_z.jpg

view after 90% of the cutting they are cut as high as i can go with out cutting the doors or floor pans
http://farm6.static.flickr.com/5241/5232989505_e3014fa63b_z.jpg

A,B, and C brackets welded in
http://farm6.static.flickr.com/5167/5236501888_532c77c244_z.jpg

2X4 welded in and painted sorry for the ****ty pic
http://farm6.static.flickr.com/5209/5235908815_7bff9552f8_z.jpg

2x4 welded into the A pillar bracket
http://farm6.static.flickr.com/5130/5235908615_6824d80426_z.jpg

2x4 welded into the B pillar bracket
http://farm6.static.flickr.com/5125/5235908519_3514b74db8_z.jpg

2x4 welded into the C pillar bracket
http://farm6.static.flickr.com/5004/5235908399_e270d215de_z.jpg

dp96zj
12-05-2010, 10:54 PM
Just an idea: don't double post the stuff from your build thread into here. I'm sure the general consensus would agree that you post the entire process in your build thread; then simply post in here with your final product, a few "work in progress" pics, and a link to your build thread. That way there's a lot less excess "stuff" in this thread.


To keep this on track, some of you guys have built multiple bumpers (mainly fronts) over the years, and usually the latter designs are "smarter" and lighter. What recommendations would you give to someone who is just starting to work on their first bumper? Any designs to recommend or ignore? My personal favorite :flipoff2:
http://www.agitatedpancake.com/random/jeep/bumper/DSC02197.JPG

Jeeptech01
12-06-2010, 04:40 PM
It is hard to decide how you want the bumper to look until it is on the rig. My advice is to design strong brackets and install them on the rig then build off them so you can see everything take shape.

AgitatedPancake
12-06-2010, 08:11 PM
Haha we all gotta start somewhere eh? The second revision was a little better!
http://www.agitatedpancake.com/random/jeep/barrett/laborday09/resized/DSC03496.jpg

I think the building of the protection is good to include, so as people find the thread while searching for ideas, they will see everything about the project they are going to tackle, inside and out.

downtowncb
12-06-2010, 11:10 PM
http://www.agitatedpancake.com/random/jeep/bumper/DSC02197.JPG

Holy HUGE bumper :eek:

I don't think I've ever seen this.

AgitatedPancake
12-06-2010, 11:45 PM
Hahaha don't be dissin on my tank killer! One of my first fab projects evar, and it never let me down. Had a better approach angle than anything out there though :D :D

blackbeer
12-07-2010, 04:21 AM
When using box steel inside the uni for bumper brackets do you cut the box in half weld in nuts then weld box back together? Or drill holes bigger then nuts and fill gaps w weld? I'm thinking option a. But haven't seen the process and all pics can't see weld putting box back together.

For the rear is it best to use box in uni AND beneath where stock hitch is bolted? Sandwich the bottom section of uni?

AgitatedPancake did you just cap the pillars beneath rockers? Did you cut the bottom seam of the doors and reweld? Build thread?

96JGCL
12-07-2010, 05:31 AM
When using box steel inside the uni for bumper brackets do you cut the box in half weld in nuts then weld box back together? Or drill holes bigger then nuts and fill gaps w weld? I'm thinking option a. But haven't seen the process and all pics can't see weld putting box back together.

For the rear is it best to use box in uni AND beneath where stock hitch is bolted? Sandwich the bottom section of uni?

AgitatedPancake did you just cap the pillars beneath rockers? Did you cut the bottom seam of the doors and reweld? Build thread?

niether, drilling through the framerail and the box steel itself and than sandwiching with steel plate worked for me.

Since the my frame rails were gone from the 6" forward from the back, for my rear bumper i opted too drill right through the floor and sandwich it between the box steel and some very large 1/4 plate. Its held up so far.

Jeeptech01
12-07-2010, 09:56 AM
Make a nut strip and slide it into the tube then drill two holes and rosette weld the strip into the box tube. Or if the tube is thick enough you could drill and tap it.

blackbeer
12-07-2010, 12:37 PM
Make a nut strip and slide it into the tube then drill two holes and rosette weld the strip into the box tube. Or if the tube is thick enough you could drill and tap it.


That is exactly what I was not thinking of thanks

Jeep Whore
12-12-2010, 12:38 AM
i got some plans to build a bumper and i need some suggestions on where to add support to it, so its not some cheap crappy bumper that will fold in on itself when it hits its first rock. this is for the 96 ZJs because of that dip for the grille. so i'm thinking for my 93 i'll just run it flat across.

http://i996.photobucket.com/albums/af82/bigfoot4300/0bumper.png

http://i996.photobucket.com/albums/af82/bigfoot4300/0bumper1.png

93ZeeJ
12-12-2010, 01:24 AM
my armor so far ( not finished still need to finish grille and make fenders

http://i302.photobucket.com/albums/nn102/clninja/2010-11-23001622.jpg


quarter panel armor i made out of 3/16" steel.. rolled to shape of body ... and rear bumper

http://i302.photobucket.com/albums/nn102/clninja/untitled.jpg

CrawlerReady
12-12-2010, 04:01 PM
Boatsides......without doors.

Buy your metal. I picked up 2" OD .250 wall HREW for the main tube, then the support tubes are all 1.5" .120 wall HREW. Covered with 1/8" sheetmetal that will be skinned with 3/8" UHMW.


Metal for my project
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs378.snc4/46077_507799382120_330900191_229036_218986_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs421.snc4/46416_507799392100_330900191_229037_7134577_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs201.ash2/46416_507799402080_330900191_229039_4093452_n.jpg

Eh.....
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs421.snc4/46416_507799412060_330900191_229041_2441703_n.jpg

...I don't really need doors, especially since they're at the landfill.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs400.snc4/46357_507799427030_330900191_229042_7570665_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs400.snc4/46357_507799442000_330900191_229045_4280131_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs400.snc4/46357_507799446990_330900191_229046_88375_n.jpg

Braced the unibody
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs420.snc4/46357_507799451980_330900191_229047_2546567_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs420.snc4/46357_507799466950_330900191_229050_787847_n.jpg

All 5 supports ran
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs420.snc4/46357_507799471940_330900191_229051_3104104_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs389.snc4/45203_507799486910_330900191_229053_4196262_n.jpg

The A-pillar and B-pillar both tie into a support
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs389.snc4/45203_507799491900_330900191_229054_4731990_n.jpg

C-clamps FTW
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs369.snc4/45203_507799496890_330900191_229055_2899306_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs189.ash2/45203_507799506870_330900191_229057_1550475_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs189.ash2/45203_507799511860_330900191_229058_588460_n.jpg

All I was able to get done was the passenger side. Drivers side is still like it was. I'll do that in a few weekends when I get the time. School starts tomorrow....
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs154.ash2/41049_507799546790_330900191_229065_6110006_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs421.snc4/46416_507799407070_330900191_229040_2329347_n.jpg

Just for kicks. Before/After
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs154.ash2/41049_507799541800_330900191_229064_2337872_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs314.snc4/41049_507799536810_330900191_229063_6275671_n.jpg

indy242003
12-12-2010, 04:19 PM
I built the bumpers on the front and rear, but my favorite mod (as for armor) had to be the sliders. 2"x6" 1/4 wall. They have saved my rockers several times. I have bashed them hard with no issues. They have also saved my doors several times because I constantly under estimate the width of my rig and end up bumping trees. The extra width has kept the doors opening and closing smoothly. The only thing I don't like about them is the wieght. I've been thinking hard about cutting some speed holes in the bottom with a hole saw to lose some wieght. Just don't know if it would be worth it.

K2
12-22-2010, 03:31 PM
i got some plans to build a bumper and i need some suggestions on where to add support to it, so its not some cheap crappy bumper that will fold in on itself when it hits its first rock. this is for the 96 ZJs because of that dip for the grille. so i'm thinking for my 93 i'll just run it flat across.

http://i996.photobucket.com/albums/af82/bigfoot4300/0bumper.png

http://i996.photobucket.com/albums/af82/bigfoot4300/0bumper1.png

You got that from Google SketchUp right? I talked to a guy who just sent out that drawing and had it cut on a plasma/water table. He said it fit perfectly and there was no grinding. I had a friend put it into another CAD program and there were some overlaps that were not to serious. I did notice the notch for the 96+ and have thought about how to make it flat, I would love to see what you came up with. I was thinking of just going flat on top and changing the angle of the fairlead mount to meet in the same spot. it is now just higher. Also we rounded the corners on top under the turn signals. There is a small gap there when assembled, just a fit and finish item.

I am thinking of making it out of aluminum. Aluminess (http://www.aluminess.com/) makes some for big vehicles so I am guessing they should be fine for small er rigs. My only question is how thick of al do I need and how does it hold up to rock crawling. I am sure these Sportsmobiles don't do to much of that.

EDIT: I just remembered, it also sat a little low. He did cut the bumper supports and they impeded the bumper sitting all the way up. There was almost an inch gap under the lights as well.

ZJ TINS
12-22-2010, 05:48 PM
Aluminum =$$$$$

Jeep Whore
12-22-2010, 06:18 PM
You got that from Google SketchUp right? I talked to a guy who just sent out that drawing and had it cut on a plasma/water table. He said it fit perfectly and there was no grinding. I had a friend put it into another CAD program and there were some overlaps that were not to serious. I did notice the notch for the 96+ and have thought about how to make it flat, I would love to see what you came up with. I was thinking of just going flat on top and changing the angle of the fairlead mount to meet in the same spot. it is now just higher. Also we rounded the corners on top under the turn signals. There is a small gap there when assembled, just a fit and finish item.


Yea I got it from google SketchUp.

I haven't cut it out yet. But my plans for the 93 edition was to make the piece that runs under the lights the same width all the way across and then add another inch to the winch guard there.

So when I get the money for the steel I'll post pictures of the build up on it.

K2
12-22-2010, 06:31 PM
Aluminum =$$$$$

Yes, but since I am doing the work I am saving there. I also like the idea of it being lighter. I just need to figure out how much lighter it will be with the thicker al vs thinner steel.


Yea I got it from google SketchUp.

I haven't cut it out yet. But my plans for the 93 edition was to make the piece that runs under the lights the same width all the way across and then add another inch to the winch guard there.

So when I get the money for the steel I'll post pictures of the build up on it.

Look for someone to get the steel and cut it for you. You may be able to buy a sheet and make 2. You can sell one and end up having yours paid for.

Jeep Whore
12-23-2010, 01:17 AM
Look for someone to get the steel and cut it for you. You may be able to buy a sheet and make 2. You can sell one and end up having yours paid for.

I have a buddy in Fallbrook that has a plasma table. i'm sure i can get them cut that way. I calculated the sq feet needed for the 96 edition. Its just under 9sq ft. As you see it there. (not including the frame mounts.)

K2
12-23-2010, 12:55 PM
I have a buddy in Fallbrook that has a plasma table. i'm sure i can get them cut that way. I calculated the sq feet needed for the 96 edition. Its just under 9sq ft. As you see it there. (not including the frame mounts.)

Cool is that 9'^2 total or what you need to fit it all on one sheet? Also I am sure it is real close for the 93-95 to make that part flat. You are removing the step and adding it up front.

The one I saw he opened the holes in the bumper support and used tube, 2"X3" I think, to go into the "frame". I liked that and I am also thinking of making the winch mount different. A flat plate all the way across there as well, in 1/4" steel or 1/2" al depending on my material choice.

Dave had an idea a LOOOONG time ago and MtnWJ did something similar, where you take out part or all of the front cross member, and you can move the winch further back to get a better approach angle. Pre-weld in a new cross member or at least a bar to hold everything up front in place while you cut out the old and put in the new.

Jeep Whore
12-23-2010, 01:43 PM
Dave had an idea a LOOOONG time ago and MtnWJ did something similar, where you take out part or all of the front cross member, and you can move the winch further back to get a better approach angle. Pre-weld in a new cross member or at least a bar to hold everything up front in place while you cut out the old and put in the new.

You mean like this?
http://i996.photobucket.com/albums/af82/bigfoot4300/IMG_4044.jpg

K2
12-23-2010, 03:53 PM
Yes, that is bad ass! Whos is that? I would love to see pics with the grill off.

it usually runs fine
12-23-2010, 03:54 PM
^^^^^^^
Whos jeep is that? Link to build thread?

Jeep Whore
12-23-2010, 05:17 PM
I don't know the guy i just met him out in the desert over thanksgiving. He told me he lives in SF
heres more pictures.
http://i996.photobucket.com/albums/af82/bigfoot4300/IMG_4045.jpg
http://i996.photobucket.com/albums/af82/bigfoot4300/IMG_4043.jpg
http://i996.photobucket.com/albums/af82/bigfoot4300/IMG_4051.jpg
http://i996.photobucket.com/albums/af82/bigfoot4300/IMG_4039.jpg
http://i996.photobucket.com/albums/af82/bigfoot4300/IMG_4040.jpg

I have more pictures of where he located his rock sliders and some pictures of the engine bay. Pm me if you want them.

97 zj Steve
12-23-2010, 11:36 PM
anymore pics of the front bumper?

Jeep Whore
12-24-2010, 07:23 PM
No sorry just hose two. If I got the guy's email I would ask him for more pictures.

5.9 ANDY
12-24-2010, 07:54 PM
that is awsome, i have now made a decision, im selling my KOR bumpers, and am going to build my own tube bumpers,

PilotAustin
12-25-2010, 01:10 AM
that is awsome, i have now made a decision, im selling my KOR bumpers, and am going to build my own tube bumpers,


shipping to texas? :D

downtowncb
12-25-2010, 09:16 PM
I have more pictures of where he located his rock sliders and some pictures of the engine bay. Pm me if you want them.

Post up whatever else you have. That Jeep looks pretty bad ass with the coil overs.

AgitatedPancake
12-25-2010, 09:49 PM
NICE Andy! Definately help your approach angle!

That truck is badass too, I feel like I've had the pleasure of seeing it at Moonrocks memorial day weekend but I'm not positive. You didn't happen to ahve a chance to see if it's headlights are HID's did you? If so, he was GETTIN IT up the competition drag hill for the quads and bikes, I made some runs too but not quite as smooth haha

5.9 ANDY
12-25-2010, 10:29 PM
NICE Andy! Definately help your approach angle!

That truck is badass too, I feel like I've had the pleasure of seeing it at Moonrocks memorial day weekend but I'm not positive. You didn't happen to ahve a chance to see if it's headlights are HID's did you? If so, he was GETTIN IT up the competition drag hill for the quads and bikes, I made some runs too but not quite as smooth haha

greg, for thr next deployment, i think i will be leaving the jeep with you again, all i will say is.... practice your bending skills. lotts of tube will be bent.

AgitatedPancake
12-25-2010, 10:39 PM
Bad ACE man! That will be sick for sure, and the beauty of it is you get all this time at home behind the wheel to hammer on it, and see what you want changed/fine tuned with the whole setup as well! My plans for the nearish future include lots of tube work anyhow, so bring it on! Once I'm done with your jeep I'm doin my 9", finish up some loose ends on my jeep then dive into all sorts of tube work hehehe

Foz2814
12-26-2010, 12:48 AM
very helpful and timely TOTM...i picked up some steel this past week and am hopingto have some silders and bumpers fabbed up soon.

Jeep Whore
12-26-2010, 08:56 PM
That truck is badass too, I feel like I've had the pleasure of seeing it at Moonrocks memorial day weekend but I'm not positive. You didn't happen to ahve a chance to see if it's headlights are HID's did you? If so, he was GETTIN IT up the competition drag hill for the quads and bikes, I made some runs too but not quite as smooth haha

No I didn't ask him about his headlights.

Jeep Whore
02-26-2011, 10:49 PM
For a rear bumper should I remove the stock tow hitch assembly and just put a hitch into the bumper I'm making?

What size rectangular tube did you guys use to slide into the unibody? 2x4?

ZJ TINS
02-28-2011, 02:25 AM
For the rear to reach the second bolt you need to neck it down. i used 2 pieces of 2x2 angle 1/4" and welded them together to form a square tube (leftovers). this let me weld the nuts in the correct places so i can bolt from the bottom.

jpeterson
03-01-2011, 01:51 AM
I know this is an old TOTM, but here is some tech/pics


Body Protection
I highly recommend it so you don’t do this.
http://i53.tinypic.com/14vspol.jpg

That lead to full body protection. These are the only kind of pics I have of the doors, and the doors are long gone. I still have the plates though. (Grand slam Rubicon 2008)
http://i56.tinypic.com/10n87zn.jpg

Now the ZJ just has tube doors and rear quarter protection
http://i52.tinypic.com/sw3dl2.jpg
all the holes are countersunk and use a allen head.

Front Bumper

Front bumper is a junkyard special. It stared life as a Warn. Found it at the junkyard off an old f150 or 250. It was originally longer and square. It got cut shorter and boated out.
http://i54.tinypic.com/fx45r5.jpg
http://i55.tinypic.com/spc6k5.jpg
http://i53.tinypic.com/2pq9icz.jpg http://i54.tinypic.com/2v0mmgo.jpg


Rear bumper Overall pics
(there are extra rear pics because someone asked in my thread)


http://i51.tinypic.com/rwqdnd.jpg


http://i51.tinypic.com/2r7sjmc.jpg


http://i53.tinypic.com/bdkrhc.jpg


There is not a trailer hitch anymore and the bumper is not incorporated into it. This may have looked like one if there appeared to be one.
http://i51.tinypic.com/2zrgu2t.jpg

Mounting

Mounting, I recommend putting four of them in a square like pattern so the bumper will not move or sag.
http://i55.tinypic.com/nd8obd.jpg

You can see how it is mounted, it is just sleeved into the frail rails.
http://i54.tinypic.com/21e2u5i.jpg





http://i56.tinypic.com/2lt5xcl.jpg

Jeep Whore
05-03-2011, 11:17 PM
I know this is an old topic but I have some updates to add for making your own.

for the rear bumper i.e the one above my post, I took his dimensions and put it on autodesk so you can have all the measurements on one paper. I still have a few things to add to it like the unibody inserts.
http://i996.photobucket.com/albums/af82/bigfoot4300/0rearbumper.png

BlingblingWJBoy
12-03-2012, 12:48 PM
Jeep Whore, can you possibly post those measurements on the rear bumper, or PM them to me? Thanks!

CTeunuch
03-16-2013, 09:32 PM
Here's a quick run down of my front bumper, more in my build thread.

This was the last run with the ARB, I liked the way it looked, but it stuck out way too far and killed my approach angle. I ended up smashing it for the second time on this ledge, and it was pretty much toast at that point.

http://img.photobucket.com/albums/v89/frigidrebellion/TPFB/pizzafest1.jpg

SoI did this.

http://img.photobucket.com/albums/v89/frigidrebellion/TPFB/007-10.jpg

Then this.

http://img.photobucket.com/albums/v89/frigidrebellion/TPFB/007_zps7b71c3bf.jpg

Which gave me a much better approach angle.

http://img.photobucket.com/albums/v89/frigidrebellion/TPFB/008_zps25b06b59.jpg

But still left plenty of room for a winch.

http://img.photobucket.com/albums/v89/frigidrebellion/TPFB/005_zpsdd75f3cc.jpg

Then added some tube and painted it up.

http://img.photobucket.com/albums/v89/frigidrebellion/TPFB/new/003_zps8b0383bb.jpg

I haven't mounted the winch yet because it broke when the ARB bent, but there's plenty of room for it back there. Squashman and I have been cutting up a factory front end skid to protect the bottom of the radiator that I'll mount up soon, I'll be sure to add the pictures when it's done. Up next is a back bumper, but I haven't decided if I want to do it out of plate/box tubing, or add in some DOM to match the front.

UTChavok
04-01-2013, 12:06 PM
I really like what you did with that bumper. Probably steal some of your ideas here soon when I start on mine.