New bumpers project

[Imagineer]

I started this project several weeks ago, but took advantage of the 3-day weekend to get some welding done.
I’m building a new set of bumpers for my ’97. When I bought the Jeep, the OEM rear bumper was rotted out along the bottom and the front had a bit of a twist.

When complete these will be painted textured black and there will be 3” round LED spots (amber in the front, clear in the rear) mounted in each bumper.
These new ones are made from 1/8” steel. Each bumper is made from 10 separate pieces, plasma cut and bent using a hydraulic press.

The outer faces of the bumpers are fully welded to the edge pieces inside and out. The back panels are welded only from the outside.

So far, I have both fully welded and the front bumper is ready for paint. It attaches to the Jeep frame using the 6 OEM bolt locations.

I’m modifying the rear bumper slightly, adding separate brackets to make it easier to attach to the Jeep.

 

[Dans98TJ]

You have a nice little shop setup there. Looking forward to the completed project.

 

[Imagineer]

Got some time to work on my bumpers project. To make the mounting to the Jeep frame stronger, I made a set of brackets from 4" square, 1/2" wall steel tube. The brackets are bolted to the Jeep frame, and the rear bumper is bolted to the brackets. Only because I was already powder coating another project, I went ahead and powder coated the brackets. I'm not going to powder coat the bumpers. I want to use paint so that if I need to make any repairs, or add features to the bumpers, I can more easily touch up the paint.

Next on the to-do list is to make the wiring access accommodations for both bumpers and smooth over the sharp corners.

 

[macleanflood]

No corner protection?

-Mac

 

[Imagineer]

No corner protection?


-Mac

I suppose I can add returns on the ends. I'll play around on CAD and see what it looks like.

 

[Imagineer]

Finally found enough time to complete the bumpers.
The amber lights in the front are wired to the OEM fog light switch.
The white lights in the rear illuminate when in reverse, but also can operate via a toggle switch.