Pics from my TJ rear bumper build

Main bumper made from 2x4 rectangular tubing, .250 wall. Bolts to frame using 8 factory holes (four on each side). Holes enlarged from 3/8 to 1/2 bolts. Hinge pin for swingout tire carrier is hunk of 1.5 DOM tubing in .250 wall thickness. Hinge pivot is piece of 1.75 wall DOM tubing in .120 wall thickness (with inside diameter juuusst slightly larger than 1.50). Grease zirk tapped. Pivot is welded top and bottom, as is pin. Swingout is piece of 2x3 rectangular in 1/8 thickness, with 1.5 (120wall) round tubing bent into a inverted U, with an upright made out of 1.75 round tube (also 120wall). Total cost about $50, plus misc. scrap steel I had lying around. Had to buy just the 3 lamps (about $25) and $15 for the pieces of 1/4 wall round tubing. (I had the box tubing) Couple of extra bucks for stuff. There are two latches, a lower one as a primary latch and an upper one to prevent rattling /vibrations in the tire.

more pics, the third brakelamp from the factory was removed and re-wired into the center of the spare tire. The backup lamps are on a toggle switch.

still need to add brackets for removeable mud flaps.

Does the pivot point go all the way through the bumper? BTDT it breaks if not.

JOOP said:

Does the pivot point go all the way through the bumper? BTDT it breaks if not.

Click to expand...

The rectangular tubing was drilled with a hole saw thru the top and bottom, and the tube was slid completely thru the rectangular tube, then welded top and bottom in place. It's damn secure. 1/4 wall on both the bumper itself and the main pin.

I'm less sure about the swingout arm, as it's only 120 wall material.

What does BTDT mean?

Nice Work Tony. :awesomework:

I like it! :awesomework:

TreeClimber said:

The rectangular tubing was drilled with a hole saw thru the top and bottom, and the tube was slid completely thru the rectangular tube, then welded top and bottom in place. It's damn secure. 1/4 wall on both the bumper itself and the main pin.

I'm less sure about the swingout arm, as it's only 120 wall material.

What does BTDT mean?

Click to expand...

Been
There
Done
That

One mine the swingout arm started to twist at the pivot point.

My first attempt the pivot point wasn't through the bumper and broke off.

JOOP said:

Does the pivot point go all the way through the bumper? BTDT it breaks if not.

Click to expand...

Been There Done That!:cheer: