PDA

View Full Version : FJZ80 Gets a new bumper


Corbet
04-11-2012, 05:33 PM
I'm starting my bumper build today. Rear end is stripped of all the bolt-on OEM components. Next up, the Sawzall.

Hopefully some major progress pics tomorrow but here it is as of this afternoon.

farnhamstj
04-11-2012, 06:47 PM
Sawzall!!!!!


Remember earplugs and gloves, and of course eye protection. Safety is no accident.

Corbet
04-11-2012, 09:12 PM
So removing the rear crossmember and Bumper channel was not a bad as I thought it would be.

Pictures of the truck and the scrap pile from today. I still have a little trimming to do on the frame horns. Then assembly of the new bumper may begin.

RLMS
04-11-2012, 11:32 PM
whattcha got in the safe...he he he!!!

looking forward to the build up!!


Justin

spcruiser
04-12-2012, 09:48 AM
Glad to see new bumper is moving forward, the oem reciever served you well as a rear slider, it will be a little quieter on the trail with the gain in clearance.

Rezarf
04-12-2012, 10:29 AM
:popcorn: :D Excited to see what you come up with Corbet.

Jacket
04-12-2012, 12:39 PM
I managed to destroy a harbor freight sawzall chopping my off. Fortunately I was ~80% done before it died, and I got a full refund. I used a cutoff wheel to finish the job.

You going to do any clearancing of your frame rails for improved departure?

http://www.risingsun4x4club.org/uploads/Jacket/fzj80/rear%20bumper/003.JPG

Corbet
04-12-2012, 01:54 PM
Lunch break. Its been hard to keep focused today with the weather. Sunny then snowy, then sunny, then snowy...:mad: Had to make a trip to town for some hardware too.:banghead: So not a lot of progress this morning.

I trimmed about 3.5" inches of the bottom of the frame rail at a diagonal to 1" in from the top. I'm not doing any additional clearancing of the frame beyond what is needed for the kit.

As you can all tell from the pictures its a 4x4 Labs do it yourself kit. I got the bumper with the dual swing arms. I did not buy any of the attachments from Luke as I plan to build those myself.

I won't dwell on too many details here as most of you probably have seen these go together on MUD, but the custom items I do, I'll show in greater detail. Everything is lining up pretty well so far. Time to start burning it together after a snack.

Corbet
04-12-2012, 03:25 PM
I do have to say. My Millermatic 211 is a completely different animal on 220v. Bumper shell is tacked and first two real welds are in place. Waiting for the duty cycle to catch up. Close up of the 1/4" wing and 3/16" main shell joint.

farnhamstj
04-12-2012, 04:30 PM
:thumb:

Trapper50cal
04-12-2012, 04:33 PM
Great weld, Corbet:thumb:

Woodsman
04-12-2012, 05:16 PM
Looking good. The clearance and slide-ability of that bumper will be most excellent.

Corbet
04-12-2012, 05:28 PM
OK, now I hate the duty cycle of the 211. I definitely see why this is a home unit. For the few times I need this much power, for so long, its still a great welder. But if I had the coin I'd love a bigger machine.

This kit is coming together pretty easy. I can lift it on and off the truck solo without issue. No spindles in place yet but the complete lower bumper and receiver are all one piece. Should not gain too much more weight.

wesintl
04-12-2012, 06:00 PM
sweet, keep up the pics. you know how we all love builds. :)

Caribou Sandstorm
04-12-2012, 07:03 PM
Looks good! You do nice work!

rover67
04-12-2012, 07:25 PM
looking good!

yeah, the short duty cycle's can suck when you got it turned up.

I like to do multiple projects when welding big stuff so I can take breaks while the machine is cooling off.

Corbet
04-12-2012, 08:07 PM
Well calling it a night. Getting cold outside. I got the main bumper done for the most part. I need to attached the side tubes and finish some welding on the inside of the bumper tomorrow. Then start the swing arms and my custom project ideas.:thumb:

Pics of the progress:

nakman
04-12-2012, 10:52 PM
Looking really good! :thumb: :weld:

hey do you have any plans for the stock spare cross member & pulley thing? :)

Corbet
04-12-2012, 10:55 PM
hey do you have any plans for the stock spare cross member & pulley thing? :)

OEM spare tire hoist, yes. The cross member I cut off, no.

Inukshuk
04-13-2012, 12:48 AM
OEM spare tire hoist, yes.

;)

bgoodheart
04-13-2012, 08:30 AM
Very nice!

FJBRADY
04-13-2012, 09:23 AM
I can't weld but nice work!

Tires look flat:hill:

Air Randy
04-13-2012, 09:58 AM
I do have to say. My Millermatic 211 is a completely different animal on 220v. Bumper shell is tacked and first two real welds are in place. Waiting for the duty cycle to catch up. Close up of the 1/4" wing and 3/16" main shell joint.

Nice, I was going to ask you if you got your welder circuit in after all of that discussion, and you're still alive. Thats good.

You know, you should go out there and give that poor old 40 a hug or something, it looks lonely sitting out there in the snowstorm with no headlights.

Air Randy
04-13-2012, 10:03 AM
Is the over temp light coming on, or are you popping the breaker? I only have the MM180 and I can crank it up to wide open and do a lot of welding before it shuts down. In fact, only BJ welding on his bumper for like an hour caused it to go into thermal shut down.

Corbet
04-13-2012, 10:14 AM
I'm not popping any breakers nor have I seen the temp light. But I can tell when its getting warm by the weld bead and I just give it a rest.

The 40 will be lonely for a while:o

bgoodheart
04-13-2012, 10:24 AM
...only BJ welding on his bumper for like an hour caused it to go into thermal shut down.

I have that effect on things!

rover67
04-13-2012, 01:04 PM
I'm not popping any breakers nor have I seen the temp light. But I can tell when its getting warm by the weld bead and I just give it a rest.

The 40 will be lonely for a while:o

Nah, don't stop there, run it till it stops itself. then wait :D

My Hobart 187 will run for a pretty decent time even cranked all the way up to do 3/8" stuff. Can probably weld about 3 feet of bead before it shut itself off for a bit. I thought yours was shutting itself off.

Bumper looks good amigo, you'll love it!

Corbet
04-13-2012, 01:43 PM
I've never run until the thermo switch kicked it off.

Corbet
04-13-2012, 04:54 PM
Calling a day early. I need to run to town for work and with Marianne out of town its beers and billiards here tonight for the guys in the neighborhood. Need to be back in time to clean up.

Got the swing arms in place. Need to add the outward stops and struts, then finish welding the spindles and the rest of the internal lower bumper. Side tubes are tacked in place and again need finish welding. Tomorrow I should be able to wrap it up and build the tire carrier.

Rezarf
04-13-2012, 04:54 PM
Looking Good Corbet! I am diggin' it. I agree with the others, run it till it quits! :hill:

Inukshuk
04-13-2012, 09:12 PM
You are a master!

Romer
04-13-2012, 10:45 PM
Nice work Corbet

nakman
04-14-2012, 12:14 AM
That's looking great, Corbet, man those welds are sweet dude.


as a data point, did you disconnect the ecu? :)

Corbet
04-14-2012, 02:52 AM
as a data point, did you disconnect the ecu? :)

I did not. The recent discussion is the only time I've ever seen a reference to to doing that. So I hope I don't have any issue.

Corbet
04-14-2012, 03:49 PM
Late lunch. Got the tire on. Now I just need to pull the whole thing off and finish weld the inside of the bumper and spindles to be able to drive it.

Not sure what direction I'm going with the ladder yet. The tire carrier I pretty much just copied the 4x4 Labs design but built it from scratch. I wan't to get the hi-lift behind the tire some how. Still thinking about that. Luke generally mounts the jack on the 2nd swing arm. I might build multiple accessories for that side and don't want the have to work out a hi-lift mount each time.

Need to move the license plate somewhere too. Be nice to have it on the spare tire side.

Trapper50cal
04-14-2012, 04:27 PM
Looks great, Corbet. On a sidenote, your shop looks like a bomb went off in it:p:

Any particular reason you chose to mount on the passenger side swing arm?

Corbet
04-14-2012, 06:43 PM
Any particular reason you chose to mount on the passenger side swing arm?

I'm assuming your asking why the tire on the passenger side? My fridge will get moved over to that side as that is where my 12v outlets are. As the fridge will already be blocking my view I figured the tire won't make it any worse. Also if I'm on the side of the road changing a flat is seems more logical to have it on that side safety wise.

subzali
04-14-2012, 06:47 PM
does that big ol' tire wobble any?

Corbet
04-14-2012, 06:49 PM
does that big ol' tire wobble any?

It does some. I have not really torqued down the two mounting bolts on the swing arm yet. I figure I should wait until its powder coated before I really pinch that clamp. But its not bad considering the wheel and tire are over 100lbs.

Trapper50cal
04-14-2012, 07:05 PM
I'm just razzin yah man, makes sense on the tire being on the right side. Powdercoat? Didn't you learn from my debacle? No touch ups on powder coat and it is gonna get some scrapes...

nakman
04-17-2012, 01:45 PM
what's all that white stuff in the last pic... are the cottonwoods out early this year in Durango? :lmao: it's spring over here on the range.. :)

Corbet
04-17-2012, 08:38 PM
what's all that white stuff in the last pic... are the cottonwoods out early this year in Durango? :lmao: it's spring over here on the range.. :)

Yah, I wanted to build something so it snowed of course, for 3 of the 4 days I spent on it. :roll eyes: Made it hard to stay focused as I do't have the space to close the door behind the 80 and still work on it. Maybe I should really clean my garage...

Corbet
04-25-2012, 01:38 PM
Getting back on this today. So for the many of you who tow a trailer I'm sure are familiar with this site. It seems like every time I wheel I end up having to replace the flat 4 trailer plug on the back of my 80.

rover67
04-25-2012, 01:44 PM
yeah, those bumpers act like nice shears on rocks :)

Corbet
04-25-2012, 01:51 PM
I wanted an OEM like trailer set up that was completely protected from damage.

I took a field trip to the local Toyota dealer and priced out a Tundra/Sequoia 7 round / 4 flat trailer harness. Kind of spendy:rolleyes: Turns out Ford uses the same thing just a different pigtail. Still expensive but no too bad. Wrote down the suppliers name and found it online for much less. About $50. http://www.etrailer.com/Wiring/Hopkins/HM40975-11998.html

Decided on a 3"x6"x1/4" rectangular tube to french it into the bumper like the receiver is from 4x4 Labs. Had a local fab shop cut (plasma table) a new backing plate to match the tube and this is how it turned out. I'm very happy. If I do manage to get a rock in there and smash it, I should be able to find a replacement on the road just about anywhere for some time. Or just steal one of Randy's new F350:bolt:

Enjoy the pics.

corsair23
04-25-2012, 03:51 PM
Very Nice :thumb:

I have a similar one, and it is tucked up under the bumper where it is protected. Much cleaner install the way you did it but I really didn't want to try and cut through both my crossmember and my Slee rear bumper. It is a pain to get to so your solution is mucho better :)

bgoodheart
04-25-2012, 04:29 PM
Slick!

Corbet
04-25-2012, 08:21 PM
Got the ladder built this afternoon. 1.5" round tube with 1.25" square steps.

I need to figure out where to mount the license plate, back up light, and Hi-Lift jack. I also plan to build a work light much like the Kaymar unit. I might rework the tire carrier a little but I think I'm probably going to end up going to Cruise Moab as is for now. Too much another stuff to do before leaving Sunday morning.

smslavin
04-25-2012, 09:39 PM
wow. that came out awesome. :thumb:

Inukshuk
04-25-2012, 10:12 PM
seriously slick

farnhamstj
04-25-2012, 10:53 PM
nice work.

rhyary
04-26-2012, 10:02 AM
Corbet,
Nice work.
Call me before you finish. I want to talk to you about the stops. I have workd an idea with Luke that can work great for future bumpers. It looks like you are in a spot where you can still utlize the idea

Rami
(518) 496-4429