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View Full Version : Crossmember Beef Up!


Big John
01-09-2010, 05:57 PM
I see a lot of guys buying/building bumpers for first/second gens without putting much thought into the stock mounting points. The upper mounts are usually in such bad shape that they are hardly worth using.
IMO if you install and aftermarket bumper, especially one with any kind of stinger which add's more leverage, reinforcing the crossmember is an absolute must.
I did this a couple years ago, but ran across it the other day and figured I share. :weld:


First I cut off the worthless upper mounts.
http://www.jeepaholics.com/support/files/bigjohn/20070905163627_Copy%20of%20IMG_2763.JPG

I made new ones out of 2"x2"x1/4 wall. I cut off the back of the tube and welded a 1/2" nut inside thus eliminating at least a couple of metric bolts, then welded the new (FROR) crossmember brace in front of that.
http://www.jeepaholics.com/support/files/bigjohn/20070905164907_Copy%20of%20IMG_2751.JPG

Added some gussets
http://www.jeepaholics.com/support/files/bigjohn/20070905165327_Copy%20of%20IMG_2756.JPG

Done
http://www.jeepaholics.com/support/files/bigjohn/20070905165517_Copy%20of%20IMG_2758.JPG

FROR bumper installed
http://www.jeepaholics.com/support/files/bigjohn/20070905165724_Copy%20of%20IMG_2759.JPG

I normally would have made my own bumper, but Brians bumpers are beefy as hell. I've pulled some pretty crazy stuff with this setup with no worries. Pulled some rather large trees off of houses after the tornado.
http://www.jeepaholics.com/support/files/bigjohn/20070905170007_Copy%20of%20IMG_2760.JPG

Red_Chili
01-09-2010, 06:33 PM
Brian's stuff is hell for stout for sure.
Dang it though, to the best of my knowledge he stopped making that front bumper!!!

FWIW, I copied his lower wings when beefing up the Chili's bumper (made by Brian's brother... or should I say, started by Brian's brother). The only other thing I did was put some bolts on the bottom in shear, and welded in some nuts to the BOTTOM of the crossmember. That way you have a couple bolts in tension, and a couple in shear... and it doesn't move at all.

Probably not necessary with Brian's bumper though. Wish I had one.

Big John
01-09-2010, 07:41 PM
Brian's stuff is hell for stout for sure.
Dang it though, to the best of my knowledge he stopped making that front bumper!!!

FWIW, I copied his lower wings when beefing up the Chili's bumper (made by Brian's brother... or should I say, started by Brian's brother). The only other thing I did was put some bolts on the bottom in shear, and welded in some nuts to the BOTTOM of the crossmember. That way you have a couple bolts in tension, and a couple in shear... and it doesn't move at all.

Probably not necessary with Brian's bumper though. Wish I had one.
Having a couple bolts in shear certainly isn't going to hurt. I've seen guys go to the upper body mount as well.
AFAIK he has stopped making it.
I've also lifted 2500+ lb boulders and moved them around my yard with this setup. Pretty sure it isn't going anywhere.