Redesigning the front bumper

I really haven't been happy with the front bumper/frame on my cj5 so I decided to do a major redesign. I'm looking for something a little more sporty and finished looking.

Started by cuttin' off some of the old bumper/crossmember.


Used some 2x4 box tubing to reinforce the frontend. This stuff is 1/4" wall, WAY overkill, buts its all the steel place had in short pieces.


After that I spent a long time figuring out how to bend this hoop. I really need to get a real tubing bender! Luckily this came out ok.


More pics to come tommorrow. I have to add some bracing to the hoop and strap the front frame rails. Also have a tricky towbar/shackle mount to engineer. Should be interesting if I can pull it off tommorrow.

Enjoy,
Kevo

 

Looks good Kevo!

 

Looks great!!

So how did you bend the tube so nicely without a bender?

 

Yea, what joe said.
Inquiring minds want to know!!

 

Oh, I have one of those cheesy harbor freight pipe benders. It works, just barely. It will only bend certain sizes of pipe well: 1/2", 1", 1 1/2". It will not bend 3/4" or 1 1/4", even tried packing with sand. The bends turn out ok. If you look closely at 90* bends you can see it starting to kink in spots. Also, the way this thing bends its difficult to figure out where to start a bend to come up with the right shape. For bumpers, sliders and spare tire carriers the pipe and pipe bender work ok. I definately wouldn't build a cage with it though.

One of these days I'll get a real TUBING bender.

Kevo

 

Yeah I thought about picking up a harbor freight pipe bender to make stingers, bumpers, tire carriers, etc.. out of pipe. I would like to add a small hoop to my front bumper similiar to yours.

Hopefully I'll have a bender someday

 

Looks gud. I've been thinking about some kind of real mild hoop type thing. Still thinking. Design a spot for the winch?

 

Well I didn't get to finish it today. Ran out of time and energy. Still need to add two braces and the shackle/towbar mounts.

I should have plenty of room for when I get a winch. It would be neat to drop it down into the frame area and have the cable come through the front crossmember. Its strong enough to do that. Unfortunately the steering box looks like it would be in the way and I'd have to cut the crossmember under the grill out substantially.

Anyhow some semi done pics.






Enjoy!
Kevo

 

Really cool looking!!! I like it mucho!!!!

 

The Harbor frieght bender can be used with patience. You HAVE to use pipe, i prefer sched .40, if you try to use tube or DOM it will not fit the dies that come with it.

 

Thats a hell'uva stinger ya got there!

Did a little more work to it this weekend. Unfortunately I had to some work to pay off jeep parts so I didn't get much personal wrench time in this weekend even thought I was at the shop all weekend. Finnaly got the shackle/tow bar mounts in and painted the whole thing black.

Heres a shot of the shackle installed.


Now heres a shot of the tow bar bushings. Probably won't use the sleeve and I'll have to make a folding tow bar for this to work. The idea is to have a folding tow bar that I can use if need be to get home. Just insert bushings, assemble the tow bar and hopefully hitch a ride somehow.


Overall shot.


Enjoy!
Kevo

 

Looking good Kevo