DIY Aluminum Front Bump Stops - JKowners.com : Jeep Wrangler JK Forum
 
LinkBack Thread Tools Display Modes
post #1 of 18 Old 07-14-2012, 05:39 PM Thread Starter
Granite Guru
 
alex00's Avatar
 
Join Date: Jul 2011
Location: Auburn, CA
Age: 43
Posts: 143
Feedback: 0 reviews
DIY Aluminum Front Bump Stops

I'm getting impatient waiting for my lift to arrive, so I decided to take a stab at making my own bump stops. I ran down to the local scrap metal store and bought a 2.5" x 9.5"ish aluminum cylinder for $15. Borrowed my buddies DeWalt chop saw and got to work. Using a $5 center finding tool and a selection of drill bits, I made quick work of it.

Running a line of masking tape down the length made the cut marks much easier to see. A smaller pilot hole made countersinking the holes much easier, than trying to do it after the bolt hole was drilled. Cut the pucks, mark the centers, drill a pilot hole, countersink for the bolt head, and drill the bolt hole. Lather, rinse, repeat. The chop saw and drill press cut through the aluminum like butter.
















alex00 is offline  
Sponsored Links
Advertisement
 
post #2 of 18 Old 07-15-2012, 01:31 PM
JKO Addict!
 
rdlynch2's Avatar
 
Join Date: Jul 2011
Location: Albany NY
Age: 34
Posts: 3,175
Feedback: 1 reviews

You wanna make me a couple 2 inchers on the cheap?

2008 Black 2Dr 6spd D30/44
RK 2.5 X-Factor | Synergy tie rod | 35x12.5 MTRK's | BFH front | Genright rear | Yukon 5.13's | ARB front locker | Warn M8000 w/MasterPull synthetic | Rigid 10'' E-series
rdlynch2 is offline  
post #3 of 18 Old 07-15-2012, 02:21 PM
JKO Addict!
 
Goodysgotacuda's Avatar
 
Join Date: May 2009
Location: Denton, TX
Posts: 13,230
Feedback: 1 reviews

What blade did you use on that saw for the aluminum?

SOLD - '09 2dr Rubicon - 1.0Gal | 6spd | 37s | 4.88s |
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
| OR-Fab cage | Poly Cage | BFH Front | XRC Rear | XRC12 Winch | Walker Evans Beadlocks |

Retired from the Jeep community, for now.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Goodysgotacuda is offline  
Sponsored Links
Advertisement
 
post #4 of 18 Old 07-15-2012, 06:30 PM Thread Starter
Granite Guru
 
alex00's Avatar
 
Join Date: Jul 2011
Location: Auburn, CA
Age: 43
Posts: 143
Feedback: 0 reviews

Quote:
Originally Posted by Goodysgotacuda View Post
What blade did you use on that saw for the aluminum?
It's the DeWalt 7747 blade, 70 tooth metal cutting blade. It's the one that came with the DW872 saw. This damn saw cuts circles around my DeWalt with abrasive wheel. I may end up buying one. I'm sure at some point my buddy is going to want his back.
alex00 is offline  
post #5 of 18 Old 07-15-2012, 06:34 PM
JKO Addict!
 
Goodysgotacuda's Avatar
 
Join Date: May 2009
Location: Denton, TX
Posts: 13,230
Feedback: 1 reviews

Quote:
Originally Posted by alex00 View Post
It's the DeWalt 7747 blade, 70 tooth metal cutting blade. It's the one that came with the DW872 saw. This damn saw cuts circles around my DeWalt with abrasive wheel. I may end up buying one. I'm sure at some point my buddy is going to want his back.
Nice, those are extremely nice saws..unfortunately the saw and blades are $$

SOLD - '09 2dr Rubicon - 1.0Gal | 6spd | 37s | 4.88s |
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
| OR-Fab cage | Poly Cage | BFH Front | XRC Rear | XRC12 Winch | Walker Evans Beadlocks |

Retired from the Jeep community, for now.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Goodysgotacuda is offline  
post #6 of 18 Old 07-16-2012, 08:44 AM Thread Starter
Granite Guru
 
alex00's Avatar
 
Join Date: Jul 2011
Location: Auburn, CA
Age: 43
Posts: 143
Feedback: 0 reviews

Quote:
Originally Posted by Goodysgotacuda View Post
Nice, those are extremely nice saws..unfortunately the saw and blades are $$
I'm finding that out. I've been searching for one, and can't seem to find them less than $450 shipped. Blades are another $100. My friend picked this one up off CL, for significantly less.
alex00 is offline  
post #7 of 18 Old 07-17-2012, 05:18 AM
JWP
Wheeler
 
JWP's Avatar
 
Join Date: Aug 2011
Location: Edmond, OK
Age: 39
Posts: 90
Feedback: 1 reviews

I've been told by the shop I buy my metal from they get more cuts from them than an abrasive blade. It's hard to believe, and even if it's not true, the ease of cutting, cooler temps, and lack sparks is a nice. Definitely on my wish list.

I just now wish I could find some aluminum that size in small quantities.

How did that paddle bit survive the countersinking process.

2011 Rubicon
Teraflex leveling kit
Smittybilt XRC Flares
17x9 Mickey Thompson Classic II's
35x12.50-17 Goodyear MTR
JWP is offline  
post #8 of 18 Old 07-17-2012, 07:35 AM Thread Starter
Granite Guru
 
alex00's Avatar
 
Join Date: Jul 2011
Location: Auburn, CA
Age: 43
Posts: 143
Feedback: 0 reviews

Quote:
Originally Posted by JWP View Post
I've been told by the shop I buy my metal from they get more cuts from them than an abrasive blade. It's hard to believe, and even if it's not true, the ease of cutting, cooler temps, and lack sparks is a nice. Definitely on my wish list.

I just now wish I could find some aluminum that size in small quantities.

How did that paddle bit survive the countersinking process.
I was so sold on the saw I found one at a local pawn shop and bought it. Saved a couple hundred off the new price. Let's see if it lasts. What bugged me about the abrasive saw was that the blade always deflected, so my cuts were slightly crooked. That, and they wore down quick on thicker metal.

That paddle blade worked like a champ. It made it through six bump stops and didn't show any signs of slowing down. I figured it wouldn't work, but had extras so it was worth the sacrafice. The big difference was the pilot hole. If I used the paddle after drilling the bolt hole, it wobbled around too much. Small pilot hole, and it was smooth and straight.
alex00 is offline  
post #9 of 18 Old 07-17-2012, 08:53 AM
JWP
Wheeler
 
JWP's Avatar
 
Join Date: Aug 2011
Location: Edmond, OK
Age: 39
Posts: 90
Feedback: 1 reviews

Quote:
Originally Posted by alex00 View Post
I was so sold on the saw I found one at a local pawn shop and bought it. Saved a couple hundred off the new price. Let's see if it lasts. What bugged me about the abrasive saw was that the blade always deflected, so my cuts were slightly crooked. That, and they wore down quick on thicker metal.

That paddle blade worked like a champ. It made it through six bump stops and didn't show any signs of slowing down. I figured it wouldn't work, but had extras so it was worth the sacrafice. The big difference was the pilot hole. If I used the paddle after drilling the bolt hole, it wobbled around too much. Small pilot hole, and it was smooth and straight.
Also an issue I have with abrasive saws. Home Depot is selling one of these saws now too, I don't recall the price but it wasn't the 400+ that Northern Tool gets for the DeWalt or Milwaukee

2011 Rubicon
Teraflex leveling kit
Smittybilt XRC Flares
17x9 Mickey Thompson Classic II's
35x12.50-17 Goodyear MTR
JWP is offline  
post #10 of 18 Old 07-17-2012, 12:00 PM
JKO Addict!
 
Goodysgotacuda's Avatar
 
Join Date: May 2009
Location: Denton, TX
Posts: 13,230
Feedback: 1 reviews

Also the abrasive won't play too well with the aluminum either.


Sent via paper airplane

SOLD - '09 2dr Rubicon - 1.0Gal | 6spd | 37s | 4.88s |
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
| OR-Fab cage | Poly Cage | BFH Front | XRC Rear | XRC12 Winch | Walker Evans Beadlocks |

Retired from the Jeep community, for now.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Goodysgotacuda is offline  
post #11 of 18 Old 07-18-2012, 09:43 PM
JKO Addict!
 
RODICON's Avatar
 
Join Date: Oct 2008
Location: Gateway to the Sierra's
Posts: 5,678
Garage
Feedback: 3 reviews

Great Job!

2014 Rubicon on the build!
RODICON is offline  
post #12 of 18 Old 08-01-2012, 08:35 AM
JKO Addict!
 
rdlynch2's Avatar
 
Join Date: Jul 2011
Location: Albany NY
Age: 34
Posts: 3,175
Feedback: 1 reviews

Theounter hole is 7/8ths, what is the size of the bolt hole itself?

2008 Black 2Dr 6spd D30/44
RK 2.5 X-Factor | Synergy tie rod | 35x12.5 MTRK's | BFH front | Genright rear | Yukon 5.13's | ARB front locker | Warn M8000 w/MasterPull synthetic | Rigid 10'' E-series
rdlynch2 is offline  
post #13 of 18 Old 08-01-2012, 08:48 AM Thread Starter
Granite Guru
 
alex00's Avatar
 
Join Date: Jul 2011
Location: Auburn, CA
Age: 43
Posts: 143
Feedback: 0 reviews

Quote:
Originally Posted by rdlynch2 View Post
Theounter hole is 7/8ths, what is the size of the bolt hole itself?
Yeah... About that. I realized I made a mistake. I actually need to make the outer hole about 1 1/8" to fit the socket for the bolt. I drilled the bolt hole at 1/2", and guess what size socket I measured.
alex00 is offline  
post #14 of 18 Old 08-01-2012, 09:40 AM
JKO Addict!
 
rdlynch2's Avatar
 
Join Date: Jul 2011
Location: Albany NY
Age: 34
Posts: 3,175
Feedback: 1 reviews

Quote:
Originally Posted by alex00 View Post
Yeah... About that. I realized I made a mistake. I actually need to make the outer hole about 1 1/8" to fit the socket for the bolt. I drilled the bolt hole at 1/2", and guess what size socket I measured.
Alright, so 1 1/8th counter hole, half inch bolt hole. Got it. I got the alumimum cut already, I just need to drill the holes at some point today. To the hardware store I go

2008 Black 2Dr 6spd D30/44
RK 2.5 X-Factor | Synergy tie rod | 35x12.5 MTRK's | BFH front | Genright rear | Yukon 5.13's | ARB front locker | Warn M8000 w/MasterPull synthetic | Rigid 10'' E-series
rdlynch2 is offline  
post #15 of 18 Old 08-01-2012, 09:41 AM
JKO Addict!
 
rdlynch2's Avatar
 
Join Date: Jul 2011
Location: Albany NY
Age: 34
Posts: 3,175
Feedback: 1 reviews

Oh. One more thing, how long are the bolts you used?

2008 Black 2Dr 6spd D30/44
RK 2.5 X-Factor | Synergy tie rod | 35x12.5 MTRK's | BFH front | Genright rear | Yukon 5.13's | ARB front locker | Warn M8000 w/MasterPull synthetic | Rigid 10'' E-series
rdlynch2 is offline  
post #16 of 18 Old 08-01-2012, 09:44 AM Thread Starter
Granite Guru
 
alex00's Avatar
 
Join Date: Jul 2011
Location: Auburn, CA
Age: 43
Posts: 143
Feedback: 0 reviews

Quote:
Originally Posted by rdlynch2 View Post
Oh. One more thing, how long are the bolts you used?
I went with 3 inch bolts. There was plenty of room for longer so you can get a 3 1/2" bolt if you want. Just make sure you measure the socket you are going to use for the 1/2" bolts, and go a hair bigger on the spade bit.
alex00 is offline  
post #17 of 18 Old 10-16-2012, 08:28 PM
Rock God
 
Freshmeat's Avatar
 
Join Date: Apr 2011
Location: Denham Springs, LA
Age: 36
Posts: 1,081
Garage
Feedback: 1 reviews

Very nice write-up! I'll talk to a few of my machine shop customers and see if I can get a couple small sections of aluminum to make my own. Been doing fine without, but just flipped my drag link and need to keep the new equipment off the frame.

1988 Wrangler YJ, Q78-15s, some of this, some of that...
2014 Grand Cherokee Limited, EcoDiesel, RWD...
2013 RAM 1500 4x4, more buttons that I'm usually allowed to touch...
2007 JK X, just getting started...
Freshmeat is offline  
post #18 of 18 Old 10-22-2012, 09:03 AM
TrailDuty.com
 
PhilD's Avatar
 
Join Date: Sep 2007
Location: Texas
Posts: 5,205
Feedback: 5 reviews

Nice work! If you want to use a smaller hole for the bolt, use a hex cap bolt.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
PhilD is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the JKowners.com : Jeep Wrangler JK Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome