Custom Bumper Design

[dustin g]

I have been looking for a nice heavy duty bumper for my jeep for a couple of years now with little success. Everything on the market is either $1200 or more for a good one but then I dont like any of the styles so I have decided to do it myself. I figure if im paying out the wazzu for a bumper it better be up to my standards.
I work as a curtain wall engineer so I have access to any and all sources concerning metal of any kind or a processs of any kind. I am water jetting the parts and powdercoating everything. I dont know how to weld but the guys that do all of our welding can do some beautiful work.
So for a little feedback throuout my design and build I will keep this thread updated though I dont promise it will be in any timely fashion as I created this model 6 months ago. Posting this and getting the comments may get me going on it again then maybe rock sliders, rear bumper, roof rack... The posibilities are endless.

Here are a few renderings of my first draft of it. Lots of work to do still but the design is getting to be something im looking for. [/ATTACH][/ATTACH]

 

[dustin g]

Any and all suggestions, ideas, and most inportantly pics of yours and what you like and dont like are greatly appreciated. I also need some ideas on the mounting of it so pics of yours there too is nice.
Thanks a ton in advance.

 

[blackbetty94]

That's a nice looking bumper. I started making mine with a heavy piece of C channel. About 4 ft long. Cut and bent the ends at about a 40deg.s. I'll try and get some pics posted later. It's nothing special, but it's cheep, and basic. Kinda let's me be creative later down the road as far as adding to it.

 

[dustin g]

The thought of some 10"x4"x1/4"HSS has crossed my mind. Whould be hella strong.

 

[rez rocker]

you should also consider weight. also if offroading approach angle. mine i built is a little to long for the approach, modifying later.you can see it in the tj reader rides

 

[dustin g]

According to my cad program my current design is roughly 412lbs. What is considered "too heavy"?

 

[dustin g]

Am planning on reinforcing my frame with c channel later on when I do a long arm. Am looking into the type of style that Rusty's Off-road has so I don't think weight makes a ton of difference. I've never done this so you tell me. How does it drive the same with an extra 300+ lbs loaded on the front? Will be balanced out with a rear bumper later.

 

[rez rocker]

the weight makes a difference if in mud/snow. floating on the top is better than sinking. my bumper weights in at 175lbs

 

[Bounty__Hunter]

412 lb is WAY heavy for a bumper, consider using thinner metal where strength isn't as much as an issue. 412 is heavier than the 2.5L engine, so imagine it as the weight of another engine.
•2.5L I4, 340 lbs.
•4.0L I6, 515 lbs

 

[dustin g]

Ok thanks guys. Target weight is 175. I thought about certain parts being aluminum and removable since it will inevitably crack instead of bend. Aluminum is abundant and free from my work so I might look into that to drop some weight. Ill have to calculated it again. Maybe I screwed up.

 

[Jester32]

I like it. I think a hoop in front of the grill would look better than the bumperette Idea but I could be looking at the picture wrong. Kinda hard to see on the iPhone. To lose some weight I would shorten the side skirts for better tire clearance and I would make the top from a thinner metal as it's not really structure just looks. Just my 2 cents. I wish I knew cad.

 

[dustin g]

I like it. I think a hoop in front of the grill would look better than the bumperette Idea but I could be looking at the picture wrong. Kinda hard to see on the iPhone. To lose some weight I would shorten the side skirts for better tire clearance and I would make the top from a thinner metal as it's not really structure just looks. Just my 2 cents. I wish I knew cad.

Sometimes I wish I didn't know cad. Is there something wrong with me since I picture the world in wireframe?
Here is a reference pic I just threw together.

 

[rez rocker]

one suggestion,i made my hoop from left over muffler pipe. seems strong,yet light weight. i have slid into a tree, no damage. looks good, just try to lighten

 

[Jester32]

Nah. That's like me picturing everything at different exposures and apertures lol. Photography is my biggest hobby. I think that the bumper would be one of a kind. I can't wait to see some more.

 

[blackbetty94]

Sometimes I wish I didn't know cad. Is there something wrong with me since I picture the world in wireframe?
Here is a reference pic I just threw together.

That looks good!

 

[blackbetty94]

Here's my work in progress

 

[dustin g]

Here's my work in progress

I wish I could pull off an easy tube steel bumper but I have a zj which has lots of contours and body lines. I'm trying to keep with the scheme of the Jeep. That is perfect on CJs and YJs but would look silly on a ZJ.

 

[dustin g]

Now I'm getting into winch sizes. I need to make sure my opening is big enough for it and everything is in the right spot. I would like a removable winch so I can switch the winch front to back at any time as my custom rear bumper is next after this. What size winch will I need? I do mostly forest wheeling so it will be used mostly for moving fallen trees. Some suggestions on what you have along with the weight of your ride is helpful. Also has anyone ever used a removable winch before and how are they "removable" but still attached good enough to hold what I want it too?

 

[rez rocker]

a friend uses a removeable one.it attaches via a stinger hitch,winch sit in a cradle with handles strong yet some what heavey to pack

 

[dustin g]

As long as I can trust it to stay put under load I'm happy. I want to be able to take it off when not needed to save gas or put it on the back if I need to winch out backwards. Who makes them?