New tj owner front and rear bumper budget build

[Ryan]

A few weeks ago I purchased my first 2005 wrangler tj 4.0 auto. It already has a rough country 4" lift, sitting on cragar 15" rims wrapped in 35" bf goodrich ko2's. Dana 30 front and danna 44 rear.
My first step is to build the front and rear bumpers since I'm trying to do everything on a budget as usual lol. First up is the front bumper my goal is to spend no more then $100 on it, I want to integrate a couple cube lights in it along with the d ring mounts, here's a couple pics of the jeep as it sits now.

 

[Ryan]

Ordered a set of hella 6 l.e.d cubes lights off of quadratec for $42 a piece. They seem like a nice quality piece, can't wait to light em up.

 

[Ryan]

Starting out I am using a 4x6 piece of scrap steel from the plant I work at plus being able to use all the tools at my work is very nice, plasma cutter, torch, welder, etc.... my goal is to have a look similar to this but we will see how it turns out lol.

 

[Ryan]

Cut it down to my desired length, then cut and shaped sides and tacked it together to hold in place.

 

[Ryan]

Starting laying out the location for the lights and d ring mounts... then plasma cut out the d ring slots and cube lights. And welded the d ring mounts thru the back

 

[Ryan]

Tacked on the winch plates and frame rail mounts and gave her a test fit...

 

[Ryan]

So far for 3 hours of work $84 for the lights it's going pretty well lol. Got everything test fit last night and my goal today is to mount the lights in and weld everything up completely. And bend the 2" hoop using stainless steel pipe that was from a left over project here at the plant with this wonderful Greenlee hydraulic bender more pics to come...

 

[Rob5589]

Dude! Great looking Jeep and that bumper is coming out real nice! Dig the color matched flares too.

 

[05 Blue Unlimited]

Looks real nice...

 

[JMT]

Good work. Congrats on the new TJ!

 

[Ryan]

Dude! Great looking Jeep and that bumper is coming out real nice! Dig the color matched flares too.

Thanks brother.

 

[Ryan]

Thanks guys so far I have been happy with how it's turned out.

 

[Ryan]

So my next step was to bend up the 2" stainless hoop, my original plan was to have it 45* down on each side for a nice Tight bend, well that plan quickly faded away with not being able to find the small segment shoe for the hydraulic bender to be able to make a nice tight 45* bend, I was stuck with the large shoe so I just ended up winging it and bent it up by eye and was actually pretty happy with the results, kind of a cross between a semi 45* and a stinger hoop . After bending up the pipe I plasma cut the excess length off to where I wanted it to end up on the bumper.

 

[Ryan]

Once in place where I wanted the hoop, welded it on and gave it another test fit on the jeep and then started on mounting the cube lights in. A Lil time consuming trying to get them a 100% even with each other, kept getting a bunch of Shadows and illusions from the overhead lights and kept throwing everything off lol.

 

[Mike_H]

Looks Great!

 

[bobthetj03]

That is one stout looking bumper! Nicely done!

 

[Ryan]

That is one stout looking bumper! Nicely done!

Thanks,

 

[Chris]

Great job on the bumper, it looks great. Very original too!

 

[Ryan]

Finally got some time to finish up the bumper, painted it and mounted it on the jeep. Wired up the lights to a temporary push button switch till I can integrate it in with a stock accesory rocker switch. Really surprised at how bright the hella lights are very happy their product.

 

[derekmac]

Nice job man, I'm diggin it!