Convert a BackBone to a full Bumper

[DETOURS]

Don't think I've ever documented this anywhere, BackBone Winch Mounts always had a 2nd purpose, that being a base to build a full bumper from. Everyone's taist differs, this is simply an example of a bumper I designed off the BackBone, it actually has become fairly popular for an unadvertised product.

Metal of choice........My build utilizes 4"x2"x1/8" wall tube, being box tube, and considering shipping wght, the 1/8" wall tube can take quite a beating if ever beat'in.....reinforcement & an outstanding approach angle are also key.

The tubes added are aprox. 18" in length cut at 5 degrees, from there each outboard end is radioused, capped and ground. Inboard portions are notched to fit within the BackBone.

http://img.photobucket.com/albums/v649/Detours/bumpbuild003.jpg

Using another straight tube, clamp it to the BackBone, clamp your new pcs of tube to the temporary tube, align to the body & tack.......by doing this you'll get a perfect, flush fit with the BackBone....

http://img.photobucket.com/albums/v649/Detours/bumpbuild006.jpg

Fully weld & grind flush, welding will include flat, vertical & overhead welding, your grinding skills will now come into play.......grind to a flush, flat finish.....

http://img.photobucket.com/albums/v649/Detours/bumpbuild008.jpg

http://img.photobucket.com/albums/v649/Detours/bumpbuild009.jpg

More to come............:thumbsup:

[DETOURS]

Wrap around........

To finish the ends, I like to use 3"x2" tube, 70% of it gets hidden, so we can keep the bumper on a diet by using tube 1" smaller......(it all adds up!)

Wraps are cut 7.5" long......45 degrees on one end, 5 degrees on the other...

http://img.photobucket.com/albums/v649/Detours/bumpmod2001.jpg

After prepping, again align with a clamped tube.

http://img.photobucket.com/albums/v649/Detours/bumpmod2002.jpg

I leave gaps between the parts being welded, this is for penitration, I also run a root pass and a cover pass...

http://img.photobucket.com/albums/v649/Detours/bumpmod2003.jpg

Knowing the joint needs to be ground flush, smooth......I purposely over-weld.

http://img.photobucket.com/albums/v649/Detours/bumpmod2004.jpg

Grind......blend........and BINGO!

http://img.photobucket.com/albums/v649/Detours/bumpmod2006.jpg

Stay tuned...........:out:

[DETOURS]

So at this point, we've come this far.........

http://img.photobucket.com/albums/v649/Detours/bumpmod2008.jpg

[PEI-XJ]

looks sweet mark

[DETOURS]

Not bad so far......thanks.

From here, there are many different possibilities......but this is for a repeat customer who's bought this bumper possibly twice already (cant remember), this is his third XJ build and wants the same bumper again.....soo...........

Lets bend some tube!

Using 1.5 tube, the base starts as 50".......

http://img.photobucket.com/albums/v649/Detours/tube001.jpg

Bend aprox. 45 degrees.......

Then, position the base tube for trimming........

http://img.photobucket.com/albums/v649/Detours/tube003.jpg

[Mudderoy]

Hmmm I never thought of a tube combo bumper, that might turn out nice.

[DETOURS]

This will be the end product:

http://www.detoursusa.com/images/patrick.jpg

[Mudderoy]

Ahhh you're almost done with it then.

[DETOURS]

Ya Tony...........and you're about ready to head home from work for the day.........right? :crazy:

[hookedonxjs]

This will be the end product:

http://www.detoursusa.com/images/patrick.jpg

That is clean looking I would have got my bumpers from you but didn't know made whole bumpers when I got my jcr's the only ones I saw were your back bones. But anyway before you trip your shoe is untied. I also think you look a bit like jimmy johnson in that photo. He's gonna do it again this year too.

[Mudderoy]

Ya Tony...........and you're about ready to head home from work for the day.........right? :crazy:

Based on my years of experience (talking to you) I think you can have this completed in two hours max! :rolleye0012:

[DETOURS]

I dont have lases......:rolleyes:
Good one Tony.........:morningcoffee:

With tube in place against bumper, scribe the tube for your cut, I use a vertical bandsaw but this can be done in many ways........

http://img.photobucket.com/albums/v649/Detours/tube004.jpg

[Mudderoy]

That is clean looking I would have got my bumpers from you but didn't know made whole bumpers when I got my jcr's the only ones I saw were your back bones. But anyway before you trip your shoe is untied. I also think you look a bit like jimmy johnson in that photo. He's gonna do it again this year too.

DETOURS "Mark" can make anything. He WON'T make somethings. Like a bumper of all diamond plate. :D

[DETOURS]

Next........prep, position......measure twice, tack into place.....

http://img.photobucket.com/albums/v649/Detours/tube005.jpg

http://img.photobucket.com/albums/v649/Detours/tube006.jpg

Save the welding for later, move on to upper hoop..........;)

[DETOURS]

I retired the D plate, too much blending work.............and thats coming from a guy who burns up 80 disc's or more a month..........:character0022:

[Tural]

that's a nice bend, u got your own brake press?

[PEI-XJ]

if you were closer i would get one of those from you for sure
80 disc's a month i dont that is less then a week i went over 300 in a week last year

[DETOURS]

It's a JD Square being used to bnd the tube, that said the upper tube blank is aprox. 50.5", bent 22' in at 50 degrees........

To fit the tube to the bumper, I made cheater sleaves years ago, slide the sleeve over the tube, postion the tube, slide the sleeve down to match the pitch, then slide the sleeve up, give yourself your cut line.......

http://img.photobucket.com/albums/v649/Detours/tube012.jpg

Slide up and mark...

http://img.photobucket.com/albums/v649/Detours/tube013.jpg

Remove & make your cuts......

http://img.photobucket.com/albums/v649/Detours/tube014.jpg

Weld after correctly positioning...

http://img.photobucket.com/albums/v649/Detours/tube015.jpg

And there ya go...............

http://img.photobucket.com/albums/v649/Detours/tube017.jpg

A full bumper built from a BackBone...........

http://img.photobucket.com/albums/v649/Detours/xj010zg3.jpg

Kinda crazy, kinda fun..........

http://img.photobucket.com/albums/v649/Detours/038Billy.jpg

This was just 1 example, if you ever decide to do one yourself, please share!!

[zjrog]

I really like this bumper build. Very nice! That tube added above and below really set the bells off for me.:wink:

I have a backbone for my ZJ that was given to me recently. I'll get it installed in the next week or two, but in the back of my mind I was wanting to do something very much like this build. BUT... The Winch platform sits lower in the front of the ZJ than the one for the XJ.

[DETOURS]

Thats OK, build up the edges, then wrap around the facia.....get creative.

I have'nt offered ZJ BackBones in years, thinking about bringing them back, you got yourself a good find!

[zjrog]

Friend of mine had it on his ZJ and when he sold it, the new owner didn't want it or the winch, so my buddy kept the winch and I got the backbone. I have some 3" square tube that I need to do something with... So far all my sketches haven't given me anything I like just yet. Need to get it installed so I have a much better idea what I want to do.

Glad you still have the instructions available on your website! :)

[DETOURS]

Is it still in decent shape?
Email me some pic's. (detoursusa.com)

[hookedonxjs]

Forgot to tell you that the xj jig is pure genius. So anyway how much would a bumper like that would sell for?

[zjrog]

Yes, its in great shape really. I know it was well used. I will use new hardware when I install it though. I'll drop some pics a bit later today... It will be going on my 95 ZJ.

And I agree, that jig is really neat. Although, I might just need something like that to hang on the wall in the garage... We'll see about that this summer when I decide what to do with my 90 XJ...

[DETOURS]

A few of us use jigs like that, excellent for custom work.

I've sold those bumpers complete for 535.00 over the years, some with custom widths for exo-cages to tie to......the approach angle is ammong the best of front bumpers.....

This can also be built from a BackBone..........

http://www.detoursusa.com/images/custom01-lrg.jpg

[DETOURS]

End product in etching primer..........

http://img.photobucket.com/albums/v649/Detours/tube012-1.jpg

http://img.photobucket.com/albums/v649/Detours/tube013-1.jpg

http://img.photobucket.com/albums/v649/Detours/tube014-1.jpg

Customer wanted a light weight hitch to be added, he'll be using it for a basket for coolers & fishing gear only.

http://img.photobucket.com/albums/v649/Detours/tube015-1.jpg


:thumbsup:

[xjjeepthing]

Thats awesome. I want one, but need a rear first

[python6446]

I almost wish I would have bought your Backbone now too. I have your Tailbone and Frame stiffener/ rock sliders. Do you think its possible to build a bumper off of the Tailbone also?

[DETOURS]

Lol..........first off, thankyou for your support!

2nd.........it took me 2.5 years to make the TailBone a viable product, reusing the factory bumper skin.......I'd say someone could do it, actually....you could probably do it by making it look like OR Fab's rear tube bumper or similiar.......;)

[Mudderoy]

I almost wish I would have bought your Backbone now too. I have your Tailbone and Frame stiffener/ rock sliders. Do you think its possible to build a bumper off of the Tailbone also?

Just get a beautiful DETOURS slimline and sell the tailbone.