Hi everyone. I bought my JK in April and am getting around to starting the mods. I also bought a tube bender and will be doing most of my on fab work. So, I started the the rear bumper, tire carrier, brake light housing, and jerry can holders. This is my first attempt at large scale fabrication with 10ga steel and I thought it turned out very good. I bought the spindle from AZ to Z fabrication. I'm just going to post the pics and they tell the whole story. If you have any questions please let me know. I really wanna know what you guys think of the build. I will get a little more creative with the lines on the front bumper...

Here are the pics:

Before I started.





Bumper off



My son using his "fake " black and decker drill to "drill" a hole in the bumper cross member. Gotta teach'em young fellas!



Yellow level is checking the level of the jeep to see if I can use it to work off of. The other angle finder is checking the angle of the mounting plates for the new bumper.



The beggining of the bumper



Side view with mounting tabs welded on.



I needed a template for the curvature of the rear end so I used form poster board for all my templates.





Transferring shape to the metal.



I needed a template for a 35" tire so I used the poster board again to see how big I needed to make the cutout in the bumper for the 35" Mickey Thompson that is going on here soon.



Basic shape of the bumper taking shape. Cuttout made and welding in. Welded supports to the inside of the bumper also.







Installing the bearing races into the spindle tube.



Basic shape test fitted.





Made a template for the side pieces. Figuring out what angle to weld the pieces on at.





Quick shot of how spindle looks put together. Have to take it apart to weld it.



With sides welded on and spindle added, welded, and cleaned up.





Continued..

 

Beginning the tire carrier.







Basic tire carrier shape before cutting and weld cleanup.



Fabricating the way the tire will mount to the carrier.





This setup is made to slid in and out to accomidate different backspacing.



Tire carrier mounted and latching mechanism made.













Making the brake light housing.









Jerry can holders all fabed up and painted.



Jerry can holders all fabed up and mounted.







So, there it is. My attempt at fabrication, wadda'ya think guys? Front bumper and rock rails are next.

 

Damn that looks pretty good

 

Wow... Ok how much do you want for it. It looks better than some of the commercial bumpers....

 

very very nice! i'd love something like that.

it seems kind of deep, if you angled in the bottom towards the tires you'd get a better approach angle/departure angle from the rear, but for you strong that bumper is i'm sure it'll be just fine.
Nice Work

 

wow thats sweet

 

want to make me one =] and i will pay you for it lol its better then most of the rear bumpers i have seen out there and the only one i really like with jerry cans is the lod bumper and thats almost 1200.00 dollars =[ let me know if you would be willing =]

 

Now that's some serious talent. That is exactly what I am looking for. If you ever start taking orders, PM me and tell me how much. Very nice!!

 

I like it! The jerry cans seem a little high and I agree about the departure angle.

Red

And I second being interested in you making me one of these! Saintlouis2009@yahoo.com

 

Very nice job! You should be proud. You customized your Jeep your way.... I'd love to know how to weld...