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Discussion Starter · #1 ·
I'm getting a lot of really positive feedback regarding my winch bumper that I designed and built. If there's enough interest, I'll take orders and custom build the bumpers for others.

The bumper has a full width backbone, winch tray and brackets of 1/4" plate for strength, and the rest is 1/8" to save weight, the construction is fully boxed, fully welded inside and out, adding to the strength and also allowing it to be used for air storage. The profile is low, such as to not block airflow to the rad (always a concern with an xj), but it is a compromise with approach angle directly in front in the middle. The approach angle in front of the tires is outstanding. The brackets pass straight through to the front for D-ring Anchors. Clean lines, and stout like a Guinness. The bumper weighs in at 95 lbs completed. The winch (Warn hs9500i) is 85. The stock setup that it replaces is approx. 30 lbs (on 96+ XJs) so you're looking at a net gain of 150 lbs. At this weight, you will lose about an inch of front end height if you have the stock springs or stock spring rate, so you will have to address this issue, as with any winch bumper. It was built around my 98 so pre 96 may require some changes to design which I hope to be getting measurements for soon.

So, orders anyone? I'm asking $750CDN and will ship south. Being in Canada, you don't have to screw around with Canada Customs and brokerage fees, etc, and the incredible markup that seems to find its way onto most US products at the border. I had so much fun building mine, I'd be more than happy to do a few more. Here's a link to a few pictures of it, finished and during construction. You get an idea of how it's put together. Sorry about the pic quality.
http://hyperphoto.photoloft.com/view/Album.asp?s=cano&u=1632030&a=1168011

-kelly



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kelly klassen courtenay bc
98xj 4.0 4x4 5spd 2dr
3" custom lift, w/SBDs
hs95001
custom bumper, skids, and rockrails
all rolling on 30" bfg at's
 

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$750 including a winch?????

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'89 4.0L Cherokee Laredo
'No woman.. don't use my shifter as an oh shit handle!!!'
 

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isnt that as much as a proven arb bumper? 400-500 would have one sold to me


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WORK WEEKENDS, ALL WEEK TO WHEEL WITH LESS CROWDS
 

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Did you make it with the little buzz box in the second picture?

How do you bolt it to the body to ensure it can handle a 9,000lb (or 18,000 with a snatch block) pull?

Will it still work with the air bag?

[This message has been edited by jeeponrock (edited November 28, 2001).]
 

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Originally posted by jeeponrock:

Will it still work with the air bag?

The airbag sensor module is inside the vehicle; the bumper won't affect it.

I can't tell how the bumper is attached to the unibody beyond the stock mounting point and the short side brackets that don't appear to tie into the tow-hook "arms". You may want to consider altering the design somewhat so that the winch tray is firmly attached not only to the OEM bumper mounting brackets (which I assume you've reinforced with the angle iron pieces that came with your tow-hooks), but also is connected to the tow-hook mounting arms that continue down the outside of the unibody frame-rails.



I like the functional design. It's a bit narrow aesthetically, but that certainly optimizes your approach angle. I recall reading somewhere about minimum bumper widths. Your design looks quite narrow - would it pass a VI in BC?



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DMMcG
'98 XJ
 

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The one I'm having built is similar to this one...isn't it purdy?




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Phil M. - Kent, WA
95 XJ Sport w/Stuff
"Who cares about a list of crap, can you drive it?"

[This message has been edited by nikon_jeeper (edited November 28, 2001).]

[This message has been edited by nikon_jeeper (edited November 28, 2001).]
 

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Discussion Starter · #7 ·
The bumper doesn't use the original bumper brackets. the brackets which pass through the bumper are bolted through the 3 original holes and also welded to the tow hook brackets as well.
As for the little welder, I used it for tacking and fitting, then welded it with my buddy's Hobart 175. It does a much nicer job.
Nikon: That is one sweet unit! Very much like what I wanted to build, except that I was more worried about airflow through the rad than approach angle. This forced me to drop the tray/box on mine.
Dale: I was unaware of any limitation on bumper width. The bumper flanks the front sides by about an inch to 1.25" on each side which is a lot farther than that tin bumper that comes stock. I can't imagine the plastic facia doing anything to protect. I will have to look into this though. As for price, I based it on what it cost for materials and the labor that it took me to build it. In the little bit of checking around that I've done, an ARB goes for $650-750US in the states, others like the durango, bulletproof etc are in the same range. I'm finding that if you double the US price, that's about what products will cost you on your doorstep here in Canada in $CDN. However, like you say, it is proven, and I won't make any assumptions that mine is in the same league as an ARB. It's strong and engineered to the hilt, but I really don't like the looks of them on a Cherokee. The second main reason (after price) I designed and built my own, was that nothing out there, not even the ARB, gave me everything that I wanted: low profile in front of the rad, good approach angle, clean lines, light, solid & strong, and not look like just a piece of 2x6 channel wrapped around the front. I'm very happy with the results and would be willing to build one for anyone else who's interested, and making small changes to the design to suit someone who wants it isn't a big deal. Cheers.
-kelly

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kelly klassen courtenay bc
98xj 4.0 4x4 5spd 2dr
3" custom lift, w/SBDs
hs95001
custom bumper, skids, and rockrails
all rolling on 30" bfg at's
 

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Nikon: That is one sweet unit! Very much like what I wanted to build, except that I was more worried about airflow through the rad than approach angle. This forced me to drop the tray/box on mine.
Yeah that's what Dan (the guy whose XJ is in the pic) was worried about with his. He hasn't had any cooling probs...especially since he put a pair of small scoops on the hood. Another thing to consider is that when crawling you're not really moving fast so flow shouldn't be an issue, eh?




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Phil M. - Kent, WA
95 XJ Sport w/Stuff
"Who cares about a list of crap, can you drive it?"
 

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slim and practical
i like it! maybe after xmas,i can hook up with one.
cheers: eric


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when i die ,the jeep goes with me!
 

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Originally posted by kel1:
everything that I wanted: low profile in front of the rad, good approach angle, clean lines, light, solid & strong, and not look like just a piece of 2x6 channel wrapped around the front. -kelly
Hey I resemble that remark



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Dan
91 Cherokee, 3" body lift, 2" front lift blocks, Warn XD900i winch, custom narrowed rear seat.
 

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Discussion Starter · #11 ·
hey, Dan
I'm a form over function guy too. But then I got married. And my wife drives the Jeep to and from work every day, so you know...


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kelly klassen courtenay bc
98xj 4.0 4x4 5spd 2dr
3" custom lift, w/SBDs
hs95001
custom bumper, skids, and rockrails
all rolling on 30" bfg at's
 

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No I don't know
, are you saying theres something wrong with my 6" channel iron bumper?

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Dan
91 Cherokee, 3" body lift, 2" front lift blocks, Warn XD900i winch, custom narrowed rear seat.
 

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OMG, someone calling your truck ugly Dan? The problem is that your pick is head on. Your truck looks way better from the side, well at least I think so, lol.
 

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I think it's cute.

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90 Sub,496BBC,d60,14b,detroits f+r, 44 boggers,th400,np205,insane ,warn15000,balls of steel
 

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Wrinkled sheetmetal always makes a jeep look better


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Dan
91 Cherokee, 3" body lift, 2" front lift blocks, Warn XD900i winch, custom narrowed rear seat.
 
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