So I decided that my first welding project ever would be to build a 4x4 labs bumper. A few of us from the local club bought various kits and were able to save some on shipping by getting it all sent out on one pallet. I have had allot of fun building this so far, but I did find the instructions in another mud thread a bit lacking in some spots (4x4labs rear bumper build - https://forum.ih8mud.com/threads/4x4labs-rear-bumper-build.142286/). A few things seem to be different and the instructions are for an 80. While I am 99% done right now using just those instructions and many others have done it as well, so it isn't impossible. I just thought I would share and document my experience.
1) Open everything up and try to visualize how it all goes together. Admittedly I didn't completely do this, but it helps once you get to a section to see it in place.
2) Remove factory tow hitch, bumper shell, step plate, etc. and spare tire. This took much longer than I was planning for and I have some suggestions here.
1) Open everything up and try to visualize how it all goes together. Admittedly I didn't completely do this, but it helps once you get to a section to see it in place.
2) Remove factory tow hitch, bumper shell, step plate, etc. and spare tire. This took much longer than I was planning for and I have some suggestions here.
- PB blaster the factory tow hitch bolts ahead of time. I had to PB blast, heat, and use 1/2" breaker plus a cheater to get these loose. My rig is pretty rust free, but dang these were in there good.
- I would recomend a breaker bar instead of impact gun so you don't break away the tacked in captive nuts (more on this later)
- During or before this time it is good to check your body behind the OE bumper shell near the rear wheels. Before you even get your stuff it is a good idea to remove the screws by the rear wheels and peak in there. I had a little bit of rust, but nothing that requires body work. Honestly I will probably just give it a quick grind and spray some paint on there before final bumper install.