Several people have PM'd me asking for help in doing a riveted stubbie conversion. Items needed: manual rivet gun, 3/16 drill bit and drill, a new single bladed razor knife with extra blades and an electric angle grinder with 1/8 by 3 or 4 inch blades ( if available). Hacksaw with fresh blade, 3/4 '' masking tape and a tape measure. About 2 dozen split shank aluminum rivets, 3/16'' X 1 ''. The split shank rivets ''flower out'' on the backside of the plastic, holding the parts together much better than swell- type rivets. Step One- on the outside edge of the bumper guard run 2 pieces of the 3/4'' masking tape. from this point measure 10'' several places and run another piece of masking tape around the bumper. By measuring several points this will ensure that the bumper cap you are cutting off will be reasonably parallel to the inside cut. Step Two- Now carefully cut the pieces apart. Remember to leave the 2 brass nutserts for the bumper support attached to the the rear of the plastic bumper. See attached photos. Take a razor knife and carefully cut and trim any roughness off the cut end of the bumper and the end cap you have cut off. You will have a 10'' long piece of bumper left over on each side which will be discarded. Step Three- Allow for a 1/2 to 3/4 overlap for the new cap you have cut to fit inside the cut end of the bumper. This will give you enough room to drill and rivet the bumper ends back on. CAREFULLY notch the rear corners of the bumper cap so it will slide in the bumper and fit evenly so you can drill the rivet holes. Step Four- Decide on the rivet spacing you want and drill the bumper FIRST. Then position the cap, drill THRU the previously drilled bumper holes into the cap and set the rivets starting from the top end and working toward the bottom. Step Five- cut the ends of the steel bumper support just outside the two mounting holes for the plastic bumper. Cut the top and bottom flats back at a 45 degree angle so the plastic bumper caps will clear when bolting the bumper back on the jeep. See photos Also see stubbie bumper installed post....

 

nice write up. i must have missed it somewhere but are there final pics up somewhere?

 

Click on his "My Project-JK Gallery" and you will see finished pics. It is under his post count.

 

A few more photos attached-

 

Nice work TINMAN! Perfect mod for those looking to save some cash for other mods.

 

I like it! have not seen that done yet! congrats.

 

Nice detailed write up...Thanks for sharing....

 

That bumper is sweet. I like it. Thanks for the write up, now time to get to cuttin'.

 

Good write up, I've been thinking of doing this and you've inspired me to cut up my Jeep over Christmas holidays!!

 

well, duh, why didn't i think of that. thanks geeper.