Jolly Green Giant's Rear bumper build - JKowners.com : Jeep Wrangler JK Forum
 
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post #1 of 16 Old 11-08-2013, 09:49 PM Thread Starter
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Jolly Green Giant's Rear bumper build

The reason I decided to build instead of buy is the "high clearance" bumpers that are on the market i.e. jcr slimline dagger and ps brawler light leave an big gap between the body and the bumper. The only way it looks good is to paint everything black so it blends. I didn't really want to do that, it'd just be a lot easier to build a bumper.

So at first I was just going to trim the frame rails and leave the crossmember.


Then I decided that wasn't going to give me the angle of the bumper I wanted, so out came the Sawzall.


I made these brackets to slide inside the frame rails, they are .250 3x4 square cut to fit inside the framerails. They should be pretty stout.



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post #2 of 16 Old 11-08-2013, 09:51 PM Thread Starter
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Got a little ahead of myself and forgot to get pictures of the next couple of steps. Pretty simple I trimmed the 3/16 thick steel to fit the shape of the tub, then I cut the angle into the brackets, and capped the angle with 2'' and 6'' steel.



I did the same thing for the ends, like a puzzle and pieced it all together.





Here it is all tacked together



All welded up, just needs to be ground, should be fun!



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post #3 of 16 Old 11-08-2013, 09:52 PM Thread Starter
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Here's a couple of shots to see how much shorter the bumper is. You can see the tailpipe hanging out past the bottom of the bumper.





Couple of pics of the inside if the bumper



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post #4 of 16 Old 11-08-2013, 09:54 PM
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Looks awesome man. Great fab work
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post #5 of 16 Old 11-08-2013, 09:54 PM Thread Starter
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When I first started this project I had 35's and non beadlocks. Since I have a different offset and bigger tires now I decided to notch the bumper so I could tuck the tire closer to the tub. Since I am going to the trouble of making everything tuck up tight there's no reason not to do it right.









So, I might have went a little overboard here, I decided to cut the framerail, and mount the bottom of the bumper flush with the bottom of the framerail.








I replaced the rear crossmember with 2x2 120 wall, and some hitch material. I spaced the 2x2 up 3/16 on the hitch, so it would all be flush across the bottom.





Painted the crossmember with duplicolor bedliner,


Also painted the bumper, but in my haste to install it, I messed it up and will have to respray it.
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post #6 of 16 Old 11-08-2013, 09:55 PM Thread Starter
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I have no clue how many hours I have in this. I know it's a lot.




Just enough room.

Last edited by dcain; 11-08-2013 at 09:59 PM.
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post #7 of 16 Old 11-08-2013, 10:28 PM
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Looks great man. Now just needs some shackle tabs.


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post #8 of 16 Old 11-08-2013, 10:32 PM Thread Starter
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Originally Posted by Abacabb View Post
Looks great man. Now just needs some shackle tabs.
Went back and forth on them, I couldn't come up with a way to make it look good, and incorporate the shackle tabs. I decided that if I needed a rear recovery point I'd just use my receiver hitch. Which is all that I had before I built the bumper.
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post #9 of 16 Old 11-09-2013, 03:27 PM
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I like it. I been thinking of doing something similar for the rear of mine.

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post #10 of 16 Old 11-09-2013, 04:40 PM
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holy fawk, awesome fab work. congrats on making your own stuff! looks killer.
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post #11 of 16 Old 11-09-2013, 04:52 PM
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Very nice. Glad you took into account the beverage support.

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post #12 of 16 Old 11-10-2013, 03:40 PM
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Very nice work. What'd you use to cut the steel up?
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post #13 of 16 Old 11-10-2013, 04:05 PM
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Wow that looks great it looks better than a psc bumper

What type of welder did you use?

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post #14 of 16 Old 11-10-2013, 06:08 PM Thread Starter
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Quote:
Originally Posted by lank View Post
Very nice work. What'd you use to cut the steel up?
I used a dewalt portaband band saw, with a swag offroad stand. Does really well for my limited space. The only downfall with it is you can only cut 6 inches deep at a time, you have to "chunk" away at it.
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post #15 of 16 Old 11-10-2013, 06:10 PM Thread Starter
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Quote:
Originally Posted by manuel View Post
Wow that looks great it looks better than a psc bumper

What type of welder did you use?
Thanks, I am glad everyone seems to like it.

Welder used is a Lincoln 180 mig welder.
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post #16 of 16 Old 11-10-2013, 07:28 PM
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Nice work!

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