I wanted something different upfront, so I jumped in and created a Stubby out of an OEM bumper.


Removed the metal sub-frame and cut plastic up to the outcrops. The sub-frame, I cut to just a half inch shorter than the plastic.



The end of the bumper before creating the end caps. I used my grinder with a cutting disk instead of my sawsall. I find that grinder gives me a smoother cut.



I created end caps from the ends I cut off. There was no part of the scraps that was long enough to cover the entire opening so I had to splice to pieces together. This is end cap just placed on end of the bumper.




This is the rough end cap plastic welded in place with some rough sanding. I used plastic repair kit and more plastic welding to fill gaps and smoothing out surface.



A view of the inside of the bumper showing plastic welding. I didn't take as much care to have a smooth finish as I did on the exterior of the bumper.




This is the end of the bumper after sanding with 80 grit to roughen the surface. Then I applied adhesion promoter, after that I bedlined the ends. I only bedlined the ends. I left the middle original finish.













Bumper in place. I have another project after looking at this picture. The brush guard, when cut, gives the impression of being flimsie and weak. I will be welding a piece there to give the impression of it being heavy.




Finish product. I have a front end hitch that I painted along with the OEM hooks with HVT porcelain paint. I baked them in a large toaster oven I have for just such occasions.




By cutting the bumper to out-crops, I removed the OEM nutserts that hold the plastic to sub-frame. I simple inserted a couple of my own. The OEM nutsert is much larger than the one I used but I used 7, there were only 2 OEM nutserts. I put 4 under the topside of the bumper and 3 facing forward. I don't think there will be a problem with the nutserts but, only time will tell how well they will hold.





My next project is tube fenders I purchased from Spyder (Crusher Tube Fenders) They arrived raw metal so I have to bedline them and install. I have to wait for sunny days to do my upgrades. I don't have a garage so I bought a 10x10 tent and set it up in my backyard as a temporary garage. One thing about JEEP owners...we are resourceful...and broke...LOL.

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Jeep -- Just Empty Every Pocket!!!