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TJ front bumper on JK mod

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Old Nov 4, 2008 | 12:59 PM
  #1  
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From: Farmington, Ct
Default TJ front bumper on JK mod

The following is my attempt at putting a TJ front bumper on my JK following the idea shown in the Modified area.
I purchased a used TJ bumper from a local club member for $20. It had the factory fogs, the "bumperette" pads on the face, and the padded "end caps".
After taking everything off, the end caps were in rough shape, I had a twist in the driver's side to deal with. When I notched the bottom of the bumper to fit on the JK mounting points the twist came out.
This is what the front looks like with the JK bumper off. The JK bumper is held on with 8 18mm nuts and bolts integrated into the factory tow hooks(if equiped).


I held the TJ bumper up to the JK mounts and centered it. Then I marked with chalk where to notch the bottom as the JK mounts are taller than the TJ bumper. This shows the notches on the bottom of the bumper and the new holes for the bolts on the tow hooks to mount the bumper.


The outside holes were new holes. The inside holes were right on top of existing holes. The holes were drilled with a step bit to 9/16" as the bolts are roughly 1/2".
Also in the above picture you can see the holes made for the factory JK fogs.
I positioned them to fit between the license plate and the mounts to what looked good to the eye. I traced the circles on with a scribe and a tin of shoe water proofer that was the same size as the fogs. I cut the holes freehand slowly with a jig saw and a 24tpi blade. Then I cleaned to holes up with a dremel and a disc. That took the longest time.

Here are my initial test fit pictures and a detail from behind the bumper of the mounting point.




I painted the bumper with a flat black rattle can.

Then I mounted the fogs. In order for them to fit I also had to notch the back of the bumper to fit the diameter of the fogs. I used #6-32 x 2" machine screws, bolts, lock washers, and fender washers along with spacers cut to about 1 1/4" out of 1/2" pipe to secure the fogs. Also I added rubber washers between the bumper and first washer made out of old bike inner tube. The picture below is a detail shot of them intalled.



Then I mounted the bumper back on, connected the factory fogs to the factory connectors, and tested them. I then secured the wire harness to the back of the bumper with adhesive tie downs using 5 min epoxy for the tie downs and zip tied the harness to the tie downs. The license plate was secured with a backing plate and frame. Oh and taking the plastic air dam off made everything much easier.


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Old Nov 4, 2008 | 01:19 PM
  #2  
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Looks good sir, great imagination. I did some custom work on my front bumper on my 06 TJ Rubi couple years ago. Cut a snipe at a long angle on the bottom, narrower on the top then used some same thickness steel plate cut/welded the openings, ground down the welds to dress it up, painted and they came out really decent looking and really strenghtened the flimsy stock TJ bumper because it boxed in the ends.

started out like this


to this


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Old Nov 4, 2008 | 02:23 PM
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I am going to talk to a couple of guys I work with who are welders to see what we can do to strengthen the bumper. Yours looks sweet the way you modded it.
I'll have to keep that in mind
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Old Nov 4, 2008 | 03:19 PM
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This looks really good, im gonna talk to some guys in my club to see if they want to hook me up with a TJ bumper
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Old Nov 4, 2008 | 05:05 PM
  #5  
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eisenjj, I'll try and get those pics as soon as I can.

Not being a fabricator I have no idea what it would take to put a hoop on there. Maybe someone with more knowledge on that will chime in.
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Old Nov 4, 2008 | 06:07 PM
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that looks real clean...
I like it.
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Old Nov 5, 2008 | 12:34 AM
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Originally Posted by AlmightyCrash
that looks real clean...
I like it.
couldn't have said it better myself
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Old Nov 5, 2008 | 02:10 AM
  #8  
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Thanks for your positive comments!
THe guy who started it in the Modified section gave me the idea,
I was lucky to find a couple of local guys who wanted to get rid of their
TJ bumpers.
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Old Nov 5, 2008 | 03:21 AM
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so versus the stock bumper, how sturdy is the TJ bumper? i know its kind of flimsy but i would think it would be better then plastic
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Old Nov 5, 2008 | 06:19 AM
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that looks like a tj bumper with holes attached to a jk. just like the post says. all good.
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