Made some progress tonight. Mostly on the bumper mounts and the frame inserts. Also made a new makeshift exhaust bracket to hold things out of the way.

Here is the area cut away from where the bumper used to be. This is where my 2x4 3/16" box will slide into the frame.


Here is the box that will go in the frame.


You have to cut the driver side in order to slid it under the gas lines that cross the frame


Here is the gas line support area that the frame needs to slide under


After piece has been removed.


Holes drilled for the shackle bolt to cross through the bar.


Makeshift exhaust mount. Pretty solid actually.


Here is the new hardware that will bolt the frame inserts to the frame. 8 3/4" all-thread bolts. Should do the trick.


And one more with the bars in the jeep. Driving like this tomorrow. Hopefully no one rear ends me cause its going to destroy their car.

 

you have inspired me to get a HF welder and start learning. my passenger side rear floor is rotten.

 

what size box tube is that?

 

I've been a welder / fabricator for 25yrs now. Warms my heart to see someone getting after welding and replacing metal. I think I must have been a blacksmith in a previous life, because I live for doing fab work. Nice job, long as your welds are tied in, dont worry about looks, just besure and treat all metal surfaces with rust inhibitor. I put the roll on bedliner in my floor as well.

 

Its worth the money. Its a lot of work but honestly it gives the jeep a ton more personal value too. Do it and post pictures as you go. Thanks!


2x4 3/16" thick. Slides right in the frame almost like it was meant to go in there.


Thank you. I have always wanted to get a project like this going and I had an MJ in high school that I had all the intentions to build and it didn't happen due to the lack of skill and knowledge back then. However, my brother just picked up the MJ yesterday to start rebuilding it so he could get his rig going and I'm pretty committed to my XJ at this point. After I get my bumper work finished I will be dropping the gas tank and starting the welding. I'm going to tack along the frame rails down the floor and then seam seal after that. I'll hit it with a good primer and paint underneath and then bedline the inside. I have been dragging my feet a little with it lately cause once the tank is out I cant drive it at all til i'm completely finished which means no wheeling at that point.

 

Looks really good. Keep these Jeeps alive! Don't send them to the junkyard!!

This also makes me happy that i live in California

 

Whats Up Jeff!

 

Mine too... probably heat from the exhaust! Great job on the floor op!

 

I had talked myself out of the HF welder and decided on getting a Hobart from Tractor Supply. BUT for just starting out and learning to weld I am reconsidering this. Right now I can see me using it for light fab work and building RC's. I hear that the HF welder has a "hot" tip. How do you like that?

 

More work.

My bumper build is basically a kit at this point. All the metal is cut and ready to go, just need to wait til this weekend so i can use a bigger welder.


Test fitting the 4x4 box.


laying out all the pieces to get an idea of how it will look.


With tire carrier in place.


Close up the angle mount area.


sitting in place.


With hatch closed


Had to make a little tool to hold my bolts to slide them into the rails.




And some more work on my storage area frames.


Passenger side


And another. Not set in place, just testing the fit.

 

I live in Colorado. We don't really get rust issues here but this XJ is a transplant from the east.


The tip does get hot when you weld for a while but I don't hold the tip anyway so it doesn't really bother me. It would be nice to have a welder that can handle thicker metals but this one is awesome for odds and ends work until Im ready to step up to gas.

 

nice work man. I cant wait to see more.

 

Looks good man.

 

Here are the build pictures for the main part of my bumper. its still not finished but it is at least useable now and I can drive around as it is for now til I can finish it up hopefully next weekend.

This makes welding much easier. I may have to start shopping for a better welder.


Nuts welded to washers.


Washers cut down to slide inside 2x4 steel


washers inside frame with holes drilled on each side to weld in place.


After holes were welded shut.


A look from inside to see the washers.


Test fitting and spot welding in place.


1/4" Angle in the corners for extra strength


Angle on both sides.


After most of the welding was done.


Finally bolted in.


Tire carrier on. (not finished yet. Needs a couple more brackets)


And another angle of the tire carrier

 

just bought my jeep a few days ago. went to pull up the carpet today to see how i was gonna bolt in a storage box. ripped up the passenger corner and saw my driveway. place the carpet back, went back inside, and like a kid walking in on his parents at a bad time, tried to pretend i didnt see that. but i thank you guys very much for showing that this might actually be a do-able repair for me. still frighened tho. . thankfully this is not my dd and im only planning on beating it.