Custom, high clearance bumpers

Mike_H

Mike_H

autos are better - WRWD508
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Feb 28, 2017
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Location
Grand Rapids, MI, United States
I spent a few hours today building a rear bumpers. I'm heavily cribbing the design from @jjvw's thread where he redesigned a reinforced cross member.

I started with a Barnes plate.

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I wanted some extra tub protection, so I tacked on some extensions to the ends.

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All plated in and welded
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Stuck on the bumper.

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Then I wanted to make sure I could still carry my bikes, or a hitch basket, or get a pull... So I added a Curt 2" receiver.

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Welded that bugger in and viloa!

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Still need to grind it and add something for tie downs... Really, just more reinforcement for the receiver. It will be going to powdercoat with a bunch of other stuff I have laying around.
 
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That style bumper just covers the crossmember correct? Looks great the way you did it (y)
 
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Finished up the rear bumper tonight. Mostly ready for powdercoat. I need to drill a couple more holes near the hitch, and make sure all my mounting holes line up.

Got the reinforcement plate done for the hitch. This is a convenient place for tie downs and what not... Not safety chains, lol.
IMG_20210329_210121697.jpg

When I got the bumper, I was disappointed that the shackle mounted were not welded on both sides. Make sense, cuz it's supposed to fit flush with the cross member, so a big weld bead would be in the way. I had another idea and got my 1/2" roto-broach out. Bored a couple holes through the plate into the shackle mount and plug welded.

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I'm not a big fan of logos cut into the products I buy. I've already given them money, I don't need to also be a billboard. Plus... This thing isn't really a Barnes bumper anymore. So...I changed the logo..
IMG_20210327_151237709~2.jpg
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Finally, I fired up the grinder for little bit. Got rid of the weld beads on the ends, so they look like one piece.
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I'm really happy with how this turned out. I can't wait to get it powder coated and see how it looks with the rest of the Jeep back together.
 
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Mike_H said:
Finished up the rear bumper tonight. Mostly ready for powdercoat. I need to drill a couple more holes near the hitch, and make sure all my mounting holes line up.

Got the reinforcement plate done for the hitch. This is a convenient place for tie downs and what not... Not safety chains, lol. View attachment 238768
When I got the bumper, I was disappointed that the shackle mounted were not welded on both sides. Make sense, cuz it's supposed to fit flush with the cross member, so a big weld bead would be in the way. I had another idea and got my 1/2" roto-broach out. Bored a couple holes through the plate into the shackle mount and plug welded.

View attachment 238771


View attachment 238774

I'm not a big fan of logos cut into the products I buy. I've already given them money, I don't need to also be a billboard. Plus... This thing isn't really a Barnes bumper anymore. So...I changed the logo..
View attachment 238776View attachment 238777

Finally, I fired up the grinder for little bit. Got rid of the weld beads on the ends, so they look like one piece.
View attachment 238778View attachment 238779

I'm really happy with how this turned out. I can't wait to get it powder coated and see how it looks with the rest of the Jeep back together.
Click to expand...
Nice! Been waiting to see what you'd come up with since that bumper thread. The only question I have is, what does the new H logo stand for? 🤔
 
Wanted to update the thread a bit. Changed the title, cuz I'll post the work I'm doing to my front bumper too.

Also wanted to show what my new bumper looks like with the tub on... Got full width on the tub.
IMG_20210411_105312848.jpg

Looking down, show how little it sticks out from the tub and the corner coverage.
IMG_20210411_105320186.jpg


And from the side. I have an opportunity to rework my exhaust too, but I'm leaving it for now.
IMG_20210411_105328259.jpg



Bumpers are going out for powder coat next week.
 
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Front bumper is next. Went with a moto bilt stubby. Again, cribbing heavily in @jjvw's previous work, I added some material to slide the winch back and get it more out of harms way. Instead of cutting and welding individual pieces, I had my uncle's fab shop cut and bend the extension based on my design.

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Adjusted the fit and welded it in today...

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I think I'm getting the hang of welding...
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Almost ready to bolt on. I'm moving the winch back 2", adding 2" to the fairlead mount, sand need to drill some new holes. Then time to grind it flat so everything fits nice.

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My hockey game got cancelled tonight so I had a little bit more time to finish up the fab work on my front bumper. Got the fairlead mount modified to fit the new position of the winch. Added 2" to the ends so the winch sits level and everything is anchored properly.

IMG_20210411_191927652.jpg


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Then, it was time to grind. The weld bead needed to go, so everything would sit flat on the bumper. Here it is, mocked up with everything mounted. I may need to remake my winch cables so they fit against the grill!

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I have a whole pile of stuff to go to the powdercoaters tomorrow. Hope someone has time to get me in!

Oh... This really wasn't about weight savings, but I did save about 50 pounds from my last setup.

My XRC copy front bumper was 47 pounds and my new motobilt stubby with modifications comes in at 34.5.

The rear bumper was an EAG step style bumper. It was shockingly heavy, at 66 pounds. My new plate, with mods, is only 21. Its a nice benefit...
 
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NashvilleTJ said:
Very cool. I played until just a few years ago when they shut down my local rink. I miss it a lot.
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I really enjoy playing. It's something I picked up in my early 30s, so I didn't grow up playing... Wish I had, though. We didn't even have a team near me while growing up, so I didn't have an opportunity. I love the game though.

Before covid-19, I was playing 2x a week, but now I'm only getting one skate in. Need to pick up another one...
 
Mike_H said:
My hockey game got cancelled tonight so I had a little bit more time to finish up the fab work on my front bumper. Got the fairlead mount modified to fit the new position of the winch. Added 2" to the ends so the winch sits level and everything is anchored properly.

View attachment 242972View attachment 242973

Then, it was time to grind. The weld bead needed to go, so everything would sit flat on the bumper. Here it is, mocked up with everything mounted. I may need to remake my winch cables so they fit against the grill!

View attachment 242977

View attachment 242978

I have a whole pile of stuff to go to the powdercoaters tomorrow. Hope someone has time to get me in!

Oh... This really want about weight savings, but I did save about 50 pounds from my last setup.

My XRC copy front bumper was 47 pounds and my new motobilt stubby with modifications comes in at 34.5.

The rear bumper was an EAG step style bumper. It was shockingly heavy, at 66 pounds. My new plate, with mods, is only 21. Its a nice benefit...
Click to expand...
If you still can, shift the fairlead mount back so that the face of the hawse is at least flush with the face of the bumper.
 
jjvw said:
For protection, in the event that it matters. It's something I wish I had thought of on mine.
Click to expand...
I actually thought about where it should go, and ran out as far forward as I could, to try and minimize the chance of the rope getting into the shackle mounts on a side pull. Probably a much better chance of damaging the fairlead in a front "collision" vs that extreme of a side pull.
 
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