DETOURS
04-21-2011, 08:10 AM
http://img.photobucket.com/albums/v649/Detours/xj010zg3.jpg
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
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
So at this point, we've come this far.........
http://img.photobucket.com/albums/v649/Detours/bumpmod2008.jpg
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
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
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..........;)
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
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:
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!!
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
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
So at this point, we've come this far.........
http://img.photobucket.com/albums/v649/Detours/bumpmod2008.jpg
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
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
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..........;)
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
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:
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!!