100 Series Front Bumper Build. Suggestions? (1 Viewer)

[corleykj]

Finished product:

Start of thread:
I decided to try building a front bumper for my 1999 100 about two weeks ago, with no real bumper building experience. I really wanted to order one from two specific MUD vendors, but I have more time than money...so I will attempt a bumper build myself. I have enjoyed welding as a hobby for years, and I currently teach some welding in a high school. I have done FJ40 metal fab work (bumpers and sills) but was always intimidated by the 100 series lines and geometry. I think this bumper might be bumper build 1 of 2 (or more if people are interested...hint hint). Anyways, I am not done with the bumper, but want to know suggestions you may have for my next bumper build after this. If I finish this and like it then I will install it on my 100, if not I will make another one for myself. After I get one installed on my 100 I will be making a friend another bumper. Who knows after that.

Thanks in advance Mud, and any suggestions will help now or in the future.

Goals of my "homemade" front bumper:
Fit an Engo 12000 winch or similar.
Be able to protect the front of my vehicle from an antelope running into me at 60 mph
Good clearance/approach.
Esthetically pleasing...the toughest part I think.

Specs:
3/16" mild steel outer plate
3/8" winch plate 1/2" winch plate (I will probably change to 1/4")
Most parts were CNC cut on a plasma table
The pieces have been mig welded using .035 wire.

Current issues:
-Some holes were made using a hand torch and are really rough! The next one will have all holes punched or cut using a cnc.
-Trying to get the winch plate bolted to the frame and cross member was an interesting task that made for some ugly work...but will be extremely strong.
-I don't have the light hoops or upper tubing work complete yet.
-I need to cut holes for 4" round LED lights (waiting on lights to proceed.
-The angle of the fairlead opening looks steep, but up close it seems to have more than enough clearance for my cable without it touching. If not I will be making some changes to the fairlead opening.
-I am having trouble figuring out a spot for d rings that would be strong. I am leaning towards d ring mounts to the right and left of the fairlead opening, so I can weld them to the winch plate and keep them in line with the frame rails for strength and stability.
-Last challenge...I AM INPATIENT AND WANT THIS DONE ASAP.

I look forward to your input, if not for this bumper for my friends we will start on soon.

View attachment 1001469 View attachment 1001470

 

[Odyseuss]

Sounds like you are covering most of the bases. I look forward to seeing the finished product. If you have the time keep at it but don't rush it.

 

[Manhattan]

Really nice work! I've always been jealous of you guys with fab' skills.

Your prototype reminds me a bit of what Jason Demello has been doing with the FJ Cruisers. He (http://www.demello-offroad.com/shop/catalog/) made the bumper for my FJ Cruiser. (below)

Initially, your prototype looked a bit heavy - lots of flat panels. But, I think once you add the hoop, the cut-outs for lights, etc, it'll break it up and have the effect of "lightening" the look.

The Demello bumper is a good "go-by" for your design... look how Jason has matched the lines of the bumper so well with the lines of the truck - the panel intersections, the grille lines, etc. It nets a very fitted or custom look - unlike the ARB one-size-fits-all approach.

If I were to offer any critiques - as the guy who ZERO fabrication skills - I'd work to shorten how much the bumper sticks out. And, work to integrate the lines of the bumper with the lines of the truck. But, don't get me wrong - your bumper already looks more custom to the 100 than anything ARB has done. Again, awesome work!

 

[corleykj]

Thanks for all the input!!!
As for the red arrow showing. The line of the bumper not aligned with the corner body line...A friend of mine looked at the side view of my cardboard template and he suggested lining those lines up. Except he suggested lining it up looking at it from the side view. I do like how your suggestions would look. I am hoping to cut that corner off in the next bumper.

I really like your fj bumper.

 

[benc]

Looks great for your first bumper build! I would agree with Manhattan. If you could loose a couple inches on how far it sticks out and maybe match the angle on the side with the one on the front.

 

[corleykj]

I don't like how far it sticks out either. I will hopefully be able reduce that distance on the next one.
On the first cardboard template it didn't stick out as much as it does now, but it also left the bumper more 90 degree angles. Somehow we decided pulling it out 2" allowed us some flexibility on increasing angles. But I do agree, if I can reduce the distance it sticks out that would be more appealing.
Thanks again!

 

[corleykj]

I have searched for front bumper builds in the 100 section about once a month for the last two years and get little results for the hobby welder. I would love to purchase a custom bumper from a couple people, and may someday. But for now, I am trying to develop a bumper design that can be done without a metal brake.

Looks great for your first bumper build! I would agree with Manhattan. If you could loose a couple inches on how far it sticks out and maybe match the angle on the side with the one on the front.

I can respond a little easier from a computer than a phone...so here I go.
To reduce how far the bumper sticks out I thought about opening the front up and exposing the winch. One problem is the winch is extremely low to be below the grill and in between the frame rails in hopes it is extremely strong. I thought about raising it up and exposing it (which would make the front not as bulky) but I don't know if it is possible or would look good. This is a picture of me working in the beginning stages, which gave me the though of exposing the winch.

 

[corleykj]

Pic of exposed bumper.

 

[benc]

Your on the right track keeping the winch low! A lot of guys put the winch up high and the puts a ton of leverage and stress on the frame ends. The angle on the front looks good but I think that is what is causing it to stick out. I'm not sure if there is a difference in winch sizes, but I'm using 10000 lb winch and was able to keep my bumper @ 4 3/4in from the center of the grill to the outside of the bumper with about an inch to spare. I don't think you would want any less than that IMHO. Have you put a tape on yours yet? I'm curious to see if does stick out that far or if it's just the pics. Even with yours how it is, it's still less than the arb. Also, I'm not sure if you have ever tried it, but one thing I do when building plate bumper is cut half to 3/4 of the way through on the back side of your bend. Then you only need to weld the back. Saves a ton of welding and grinding. Any plans on a grill guard?

 

[benc]

Your on the right track keeping the winch low! A lot of guys put the winch up high and the puts a ton of leverage and stress on the frame ends. The angle on the front looks good but I think that is what is causing it to stick out. I'm not sure if there is a difference in winch sizes, but I'm using 10000 lb winch and was able to keep my bumper @ 4 3/4in from the center of the grill to the outside of the bumper with about an inch to spare. I don't think you would want any less than that IMHO. Have you put a tape on yours yet? I'm curious to see if does stick out that far or if it's just the pics. Even with yours how it is, it's still less than the arb. Also, I'm not sure if you have ever tried it, but one thing I do when building plate bumper is cut half to 3/4 of the way through on the back side of your bend. Then you only need to weld the back. Saves a ton of welding and grinding. Any plans on a grill guard?

 

[corleykj]

Thanks for your input! I think it is about 7" from the edge of my grill to the edge of the bumper. I do have space in front of the winch so I should be able to shorten that on the next one. I do have ideas for a grill guard but haven't got the bender set up yet or purchased the metal yet. I am thinking 1.5" diameter.

 

[corleykj]

Benc, where did you mount your winch? Mine is about 3 inches in front of the cross member. I didn't want it too close to the radiator. Since the cross member holes are 10" on center I could move the winch back to that and use those for a couple of my winch bolts on my next one.

 

[benc]

The bottom of my winch is about middle of the frame ends and there is prob about 3in to the radiator. The front of the winch is only 1/8in from the bumper. With the 4 3/4in it gives just enough room for my light bar. If you do end up doing a grill guard that will shrink it up for sure. It hard to tell in the pics but here are a few of mine,

FWIW, just because some people like the bumper tucked up tight, there are prob just as many that want it to stick out a little more. Iv built a lot of bumpers and I would say its about 50/50. Some want approach angle and some want more protection.

 

[corleykj]

Benc,
I really like your bumper! Nice work and thanks for the measurements and descriptions.

 

[benc]

Benc,
I really like your bumper! Nice work and thanks for the measurements and descriptions.

Thanks, yours looks really good too, most of the time it take me a good 2-3 bumpers before I come up with something I'm 100% happy with. Keep up the good work and keep us posted on the finished product.

 

[corleykj]

I am trying to trim away some metal so it doesn't scratch up my body, or touch my body if my bumper moves a little. Here is the bumper resting on a stool, not mounted.

Leds came in the mail today.
My d ring mounts are made I just need to get them fitted correctly.

 

[corleykj]

Update: D ring mounts/shackle mounts welded to the winch plate and the shell of the bumper. They have a 7/8" hole with 3/4" d rings. The recessed light tubes are cut and tacked in place. Hopefully I can put the bumper on the car later and see how things line up.

 

[r2m]

A couple of things, and I must qualify that I'm speaking for myself:

• Weight!!! This is where real engineering with FEA analysis comes in handy. Making a bumper as light as possible yet with all the strength of a heavier bumper. I've thought about aluminum. If one doubles the wall thickness of aluminum plate, it will be as strong as mild steel and still lighter. Problem is, most people don't have equipment or skills for welding aluminum.
  
• Can you do this for a 1.75" body lift without it looking stupid??
• Usually the D ring posts should come straight off the frame mount so they are integral with the frame and mount for maximum strength especially in lateral pulls.

 

[corleykj]

R2m, I do have access to equipment to make one out of aluminum, but that will have to wait until I have some more bumper experience. The 1/2" winch plate is where some serious weight is added. I will probably switch to a 1/4" winch plate on my next one. I measured the sag of my suspension at 5/8" with the bumper. As for making one for a 1.75" body lift, I have no idea. On my cad programs I should be able to do some pretty good 3d views of completed bumpers, and could try and design one for a body lift. I would think Mike with BIO would be the guy for that. My D rings are welded to the winch plate which is connected to the frame and cross member. I agree, having it double as the frame mount is the end goal, but I think I can trust this one for the situations I will get into. I am also thinking of beefing up a hook/recovery bracket to mount where the factory one mounts. Thanks for the suggestions, those are great for this project!

 

[corleykj]

Mounted with pics!
I am still trying to figure out if I am going to bend the tubing for the grill guard myself, or have a shop do it. I mounted the bumper today and it bolted up great. I have some grinding and sanding to do before I paint or rhino line the bumper. I need to make mounts for the 4" leds. I think the major part of fabrication is done for my first bumper!

Any input (negative or positive) is greatly appreciated, we will be starting on another one for my friend after Christmas.