Hey Everyone -
I thought I'd create a post to document the rear bumper I just finished building. It'll be a long one, as I took quite a few pics during the process, but I figured it might help others looking to build something similar. I'll try to explain everything as I go, but feel free to ask any questions.
In case anyone is wondering, the spindle I used is the Heavy Duty Tire Carrier Hinge Kit with Double Shear Bracket from comp4x4.com, and the latch mechanism is this one from Poly Performance/Synergy Suspension. Side note: both products are highly recommended! Also, check out the video on the Poly product page for the latch to see how it works - they show it much better than I could.
Anyway, here's what I started with - a 3"x5" x 3/16" wall rectangle tube. Here I drew the cut lines for the angles on the side, and the center line for the hitch receiver.
Here's the first hole cut for the spindle sleeve, and the three holes for the double shear bracket.
Here it is after making the angle cuts with that little portaband you see in the background.
I then blind drilled and tapped these three pieces of round stock to serve as nuts for the double shear bracket bolts in order to keep the main bumper body sealed for air tank use.
(Partially) Welded in.
Hole cut for hitch receiver (with a f'n dremel!
).
Hitch receiver slid in.
Welded and ground flush with the front of the tube.
A bung welded in and tapped for 1/4" NPT for the future air line.
I then went a little extravagant, and designed these on the computer then had these brackets cut out by a local waterjet guy. The top one (1/4" thick) is for the safety chains while towing, and the bottom two (3/4" thick!) are obviously the frame tie-ins and D-ring/shackle brackets. These pieces are really incredible though - the quality of the waterjet cut is second-to-none.
Here's the safety chain bracket welded to the back of the bumper along with some other bracing I just threw on there for the hell of it...
I then cut out the holes for the frame tie-in brackets - with a friend's plasma cutter this time! No more dremel BS for me...
Frame tie-in brackets welded in.
I then bent these plates to cap off the ends of the bumper.
Passenger side capped.
Driver side capped, with second hole drilled for spindle sleeve.
Spindle sleeve welded in, with spindle "press-fit" in sleeve during welding process.
Bottom tube of swingout portion welded on.
The latch mechanism I chose to use required the end of the swingout to be 1.75" round tube, so I got a piece, and slid about 4 or 5 inches of it into the 2"x2" x 1/8" wall square tube. After that, I fabbed up a little plate to cap off the open corners.
I thought I'd create a post to document the rear bumper I just finished building. It'll be a long one, as I took quite a few pics during the process, but I figured it might help others looking to build something similar. I'll try to explain everything as I go, but feel free to ask any questions.
In case anyone is wondering, the spindle I used is the Heavy Duty Tire Carrier Hinge Kit with Double Shear Bracket from comp4x4.com, and the latch mechanism is this one from Poly Performance/Synergy Suspension. Side note: both products are highly recommended! Also, check out the video on the Poly product page for the latch to see how it works - they show it much better than I could.
Anyway, here's what I started with - a 3"x5" x 3/16" wall rectangle tube. Here I drew the cut lines for the angles on the side, and the center line for the hitch receiver.
Here's the first hole cut for the spindle sleeve, and the three holes for the double shear bracket.
Here it is after making the angle cuts with that little portaband you see in the background.
I then blind drilled and tapped these three pieces of round stock to serve as nuts for the double shear bracket bolts in order to keep the main bumper body sealed for air tank use.
(Partially) Welded in.
Hole cut for hitch receiver (with a f'n dremel!
).
Hitch receiver slid in.
Welded and ground flush with the front of the tube.
A bung welded in and tapped for 1/4" NPT for the future air line.
I then went a little extravagant, and designed these on the computer then had these brackets cut out by a local waterjet guy. The top one (1/4" thick) is for the safety chains while towing, and the bottom two (3/4" thick!) are obviously the frame tie-ins and D-ring/shackle brackets. These pieces are really incredible though - the quality of the waterjet cut is second-to-none.
Here's the safety chain bracket welded to the back of the bumper along with some other bracing I just threw on there for the hell of it...
I then cut out the holes for the frame tie-in brackets - with a friend's plasma cutter this time! No more dremel BS for me...
Frame tie-in brackets welded in.
I then bent these plates to cap off the ends of the bumper.
Passenger side capped.
Driver side capped, with second hole drilled for spindle sleeve.
Spindle sleeve welded in, with spindle "press-fit" in sleeve during welding process.
Bottom tube of swingout portion welded on.
The latch mechanism I chose to use required the end of the swingout to be 1.75" round tube, so I got a piece, and slid about 4 or 5 inches of it into the 2"x2" x 1/8" wall square tube. After that, I fabbed up a little plate to cap off the open corners.
Last edited:
think you should get copyright for your product before someone market your idea especially " 120 pound hydraulic lift support for holding the swing out open " i really admire your workmanship bro...
