TOTM: Bumpers/body protection

[Jeep Whore]

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.

[93ZeeJ]

my armor so far ( not finished still need to finish grille and make fenders




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

[CrawlerReady]

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






Eh.....


...I don't really need doors, especially since they're at the landfill.






Braced the unibody




All 5 supports ran




The A-pillar and B-pillar both tie into a support


C-clamps FTW






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....



Just for kicks. Before/After

[indy242003]

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]

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.

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 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]

Aluminum =$$$$$

[Jeep Whore]

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]

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]

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]

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]

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?

[K2]

Yes, that is bad ass! Whos is that? I would love to see pics with the grill off.

[it usually runs fine]

^^^^^^^
Whos jeep is that? Link to build thread?

[Jeep Whore]

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.






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]

anymore pics of the front bumper?

[Jeep Whore]

No sorry just hose two. If I got the guy's email I would ask him for more pictures.

[5.9 ANDY]

that is awsome, i have now made a decision, im selling my KOR bumpers, and am going to build my own tube bumpers,

[PilotAustin]

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?

[downtowncb]

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]

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]

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]

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]

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]

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]

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?