The Blue Submarine *Cage and tube bumpers*

[AgitatedPancake]

Alright I took these pics to kinda think out loud.

Here it is from the inside currently strapped between the frame rails





If I go with it this high (as high as I can get it without interfering with a flat floor), I would have to cut out the indentation for the filler hoses, and create a similar design that goes in more to cover the hoses, or maybe I can chop it off in a nice fasion, and use the factory peice inboarded with some sides for it.

Also, I've decided it's about time for me to do the rear bumper as I was waiting to raise the tank so I didn't waste space in the long run. My idea right now is to use the factory hitch, but chop the center section out, rotate it 180* so the receiver is on top, weld/fishplate it back together and cut the sheetmetal in the crumple zone to acommodate it, then build a bumper off of that. I think I could make a really nice looking plate bumper off of it, and it would be small as it doesnt have to go down to cover the gas tank anymore. Opinions?

Example: cut at the white lines, flip center over and reweld w/fishplates




This is how the hitch is now:


You can see if I flipped the center it would tuck up into the crumple zone but have really nice clearance and the good beginnings for a bumper.

[rradford9]

So are you raising it up enough that you need to drill a hole through the unibody to route the filler hose?

[AgitatedPancake]

If I go with it this high (as high as I can get it without interfering with a flat floor), I would have to cut out the indentation for the filler hoses, and create a similar design that goes in more to cover the hoses, or maybe I can chop it off in a nice fasion, and use the factory peice inboarded with some sides for it.

Yeah.

[nierace]

I'd just lower it a little to use the factory filler, its still going to be way out of the way.

[Ken L]

regarding your hitch, why don't you cut at the mounting bracket and flip the brackets? I'm thinking that would be stronger.

Or just build the bumper and incorporate the hitch into it without using any of the factory stuff. That's what I did with my ZJ.

[AgitatedPancake]

I'd just lower it a little to use the factory filler, its still going to be way out of the way.

Yeah but if I can manage to do it this way and flip the hitch, there will be nothing hanging down at all back there, in fact the hitch would be the lowest part of the truck which makes it perfect for a bumper.

Ken, flipping @ the brackets is a good idea, I may do that instead. I think the hitch would be strong enough with some decent reinforcement for lateral blows and tugs. I was thinking of having a 3/16 skin with 1/8" runners on the inside going back to the hitch, then putting some gussets in the hitch mounts for the side strength.

[goldensd]

It would be best to cut at the brackets and flip them. Also, I don't know about the WJ's, but on my ZJ I also moved the crossbar back a bit on the brackets, so that it didn't hang past the rear end quite as far This is the way I built mine, and yes, the hitch makes a great base to build the bumper off of.

And I don't think you have to worry too much about the strength of the mounts since it is designed to tow with. I know I pulled a dead Scout for about the last mile out of Barret Lake this fall. I had it attached to one of my side clevis mounts, and saw no signs of anything moving.

[AgitatedPancake]

Alright so far today my focus has been on my tank skid, I already went out and priced a 4'x4' peice of 12ga. so I can cover this bad boy and have leftovers for other necessary things.

I started by drawing some straight lines and hacking off the brackets.


After that I had to sit and think for a while about how I was gunna go about this, then it came to me. Looks like its going to work like a charm.
(still has 3-4" to go up)


Right side under:


Left side under:
.

I cut off the brackets on top and any bends in the skid that made the sides not straight up and down, and was able to get the sides to slide in between the frame rails. It's actually slightly pinched enough to hold its own weight. Here are the right and left sides looking from inside.
This is the right side, the gray is the skid. It can't go up any more yet because it's bottoming out against the floorboard so I have to cut off more material.


Left side:



Once I cut that extra material off I should be able to get the skid *most* the way up, I still have to figure out how I want to strap it down as it looks like I may have to cut off the rear portion of the strap mounts. I was thinking of having the bolt end of the strap bolt to the body instead of the skid. Does anyone think that would be an issue? The only way I could see it being an issue is if I crushed the skid, but with as high and as thick as it is I dont think that'll happen.

[AgitatedPancake]

Did a lot of work getting it closer to done today, here are some pics =D
The stock filler hoses and filler neck on top of the floor:


Making it work...


Can't have fumes in the cab so...



I cut open my fuel filter because it was already dead and I wanted to see how bad it was...wow. I dont know how the jeep even ran...



Skid after all my cutting:

and with tabs


Not bad for filling a big gap I don't think (1/4" - 3/8"?)


Final product:



I get to throw it back on tomorrow, and im getting a peice of 4' x 4' 12ga. steel so I can plate the back and build the box for the filler hoses, I got somewhere between 7 and 8" more clearance out of this project, I'm VERY satisfied. The hitch is next but its gunna have to wait till after my day snow wheelin trip on thurs =D

[rradford9]

Damn, you really did get that thing high! Thats about 3 or 4 inches higher than the others I've seen. Most people just drill a hole and sleeve the unibody for the filler hoses. Can't wait to see the finished product. I'm gonna have to do something similar once the price of steel goes down a little more...

[NOTHINGMAN]

im loving this build up..thanks for posting so many detailed pics..givin me tons of ideas for where i want to take my WJ...your WJ is really looking good

[nierace]

I still think you should have raised it up more, it might get hung up on the Eiffel tower.

I shouldn't have sold you my old wheel spacers !

[AgitatedPancake]

I got it done last night at 10:30, so I could leave for a snow wheelin trip today. Talk about cuttin it close...I don't think my neighbors like hearing an impact that late. Anyways, I'm gettin ready right now but it looks like its RAINING up in the sierras right now instead of snowing. This could be a short trip =/.

I'll update pics when I get back.

[nierace]

Try not to break yo shit.

[ArloGuthroJeep]

That'll be hard for Greg I think...after all I can't think of any trips he has ever come back from w/o some nice damage

[AgitatedPancake]

I broke. Haha no im serious, pulled a strap off my front diff yoke and...set my driveshaft free. Luckily this is one of those cheap fixes =P

[AgitatedPancake]

Rewind to 2 days ago.
I ended up cutting back to where the frame rails attatch to the floorboards, where there is a about 1" wide section where the metal is 2 layers thick because of overlap.



Stitch welded in place then sealed w/RTV. Access hole for fuek pump and the filler hose cover is going to be removeable.




[img][/img]

[AgitatedPancake]

oh, and my tires hate me. I need to bumpstop both corners, trim my front bumper a little and finally cut my other rear fender.

[wjguy]

looks good man, I still need to get this mod done- I drag ass like a dog with worms.

[nierace]

Looks good - You need to trim a little more behind the rear doors, but throw in some ~5" bumpstops out back and you should be good I have 0 rubbing there now.

I've been checking out bumpstops from Fox for the front trying to figure out where to put them though...they're too short to work inside the coil.

[AgitatedPancake]

Hmm i think i am going to add some rear bump stop like you said. U talking about fox air bumps? I would love to run those in front with how little uptravel im working with. I noticed my front truss kissed the oil pan once at full flex, just a scrape so it needs to be done.

[jborushko]

[quote=AgitatedPancake;128478]


what gauge is the steel for your bumper?

[AgitatedPancake]

its 1/4"

[jborushko]

its 1/4"

ha DANG!! is it heavy!!????

thanks for the info!

[AgitatedPancake]

ehh, the whole bumper weighs less than 100lbs, I don't have a problem movin it around.