New Rear Bumper Build

[goldensd]

Started working on a new rear bumper to match the one I did for the front last year, and thought I'd get a few pics going.

The intent of this bumper is to obviously raise the departure angle (especially at the corners), provide tow points, and provide a place to store spare parts (axles shafts/fluids), by adding a removable plate on top and keeping the inside clear of bracing.

Hear, is the rough mockup of what the basic shape/clearances will be:



After looking at the mounting options, it seemed to me that utilizing the existing hitch would alleviate a lot of worries about mounting and strength, but severely impacts clearance. After looking at it, I decided to flip the tube and relocate the receiver to the top of the cross-tube. While at it, I was able to raise the tube itself, and shaved about 3/4" of the bottom of the mount. In all this raised the lowest portion of the existing hitch by almost 4 inches. On the inside of the frame I used 2" x 3" x 3/16" angle iron to provide a backing plate and increase frame strength where the hitch bolts in.

Also, to help with corner clearance, I went ahead and cut some of the extra steel out and redid the bottom corners under the tailights.

Here are some pics of the progress so far:

[DLoweinc]

Looks like it is coming along nicely. I'm interested in the final product.

By the way I'm local to you (I live in Martinez) if you need a hand sometime let me know.

[DJJordache]

if it is anything as nice looking as your front I can't wait for the pics!

[adam99wj]

looks good , i like the storage compartment feature

[jfowlzj95]

Nice, I like how this is starting out.

[fpkites]

Definitely looks good S - looking forward to what you're talking about with regard to storage space.

[goldensd]

Thanks guys, I'll try to keep the pics rolling out as I take them. So far this one is WAY easier than the front one was. I think reusing the hitch as the mount saved a huge amount of time in figuring out a solid attachment.

Dlowe, you'll have to come on over sometime and check it out. Always good to meet a fellow ZJ'er.

[tywilson88]

i love the idea for storing parts... i cant believe i didn't think of that.

[violatedppl]

could you post anymore pics on how you set up the reciever. It looks like just those two pieces of 3/16's angle. If thats it I wouldnt be to sure about pulling from it

[Cue-Ball]

Looking good man, I am sure it will turn out sweet just like most things on your Jeep.

Dirk

[93ZeeJ]

interesting.. i was planning on havin someone make me a new rear soon... ill try the same idea of using my hitch as a mounting point

[goldensd]

could you post anymore pics on how you set up the reciever. It looks like just those two pieces of 3/16's angle. If thats it I wouldnt be to sure about pulling from it

I'm re-using the existing setup, albeit slightly more reinforced around the framerails. I figure if it is strong enough to be sold as a class III hitch, then it's strong enough to work this way as well.

[goldensd]

Haven't had a lot of time to work on it lately, but did get one of the upper corners put together and tacked in today. Here's a few pics of the framework for the corner:

[96_zjlarado]

lookin real good! I like how it's nice and rounded like the tail lights on the corners. that's how i want mine to turn out.

[wheelnzj]

Shawn,

Looks good, except for the dent in your rear quarter, where did that come from? Hope to wheel with you again soon.
Going to GSW by any chance?

Ron

[Z]

Lookin' great. Do you need to add some triangulation around the sides, or will that come later?

[grandmaster]

Looks really good, what guage steel is that? I had a dent in my quarter panel and I was able to take appart the inside and get a hammer and dollie and shrinking hammer it out. Didnt look as big as yours but if you want it fixed without having to paint it you might want to try that.

[goldensd]

Shawn,

Looks good, except for the dent in your rear quarter, where did that come from? Hope to wheel with you again soon.
Going to GSW by any chance?

Ron

Unfortunately, I've got too much going on this spring to even consider heading to GSW, but hopefully I can make that one soon enough. I'd like to get some good trips in this summer though, so definitely keep me in mind when you headed up for a weekend.

That dent has been there for a while, it was actually already there at GSR last year. I just haven't taken the time to take the inside panel off to hammer it out. I have to take it out to run antenna wire for my CB so was just figuring I'd fix it then. It's really not too bad.

[goldensd]

Looks really good, what guage steel is that? I had a dent in my quarter panel and I was able to take appart the inside and get a hammer and dollie and shrinking hammer it out. Didnt look as big as yours but if you want it fixed without having to paint it you might want to try that.

Most of the dent won't even take a hammer, its just caved in, except for one small area.

The bumper will be made with a 1/8" on the upper areas that won't take many hits, and the bottom impact areas will be 3/16". I still have a lot to add around the bottom to tie everything together.

Since I'm using the hitch mount and it extends forward pretty far, I am also going to add some reinforcing tube that will tie the impact and cantilever portions back into that for a bit more support on the corners.

[goldensd]

Got a bit more done yesterday. Now have both upper sides welded in and skinned. Will still be closing in the bottoms on the sides and around the corners to add some stiffness and clean up the looks of it. Here's a few new pics:

[Matt]

Nice and clean.

[ZJ Pappy]

Looks good. I like that the sides sit flush with the fender.

[5.9 ANDY]

looking sweet dude, we should hook up some time and go wheeling.

[goldensd]

Got a lot done this weekend. Now have almost all of the major fab done and only have to fit a couple more pieces on the corners, trim the wheel wells, and then finish welding it up and getting it ready to paint. Here's some new pics:

[BLK97ZJ]

looks good.
Is the CB antenna staying there?