ARB Copy Winch Bumper ~ XJ Style

[stomperxj]

So I have always liked the look of the ARB winch bumpers for the XJ. Problem is, I could never justify spending $900 on a bumper :shock:

I started in Autocad and Google Sketchup and after about 932 revsions and tweaks I finally think I got a design I like:

On to cutting:

And throw in a few tack welds:

I'm pretty happy so far. My SmittyBilt winch is going to fit nicely and be totally hidden behind the bumper. Frame tie in plates and the winch tray will be made from 3/16. The bumper itself is 10 ga (.1345 thick). Probably throw a couple rectangular lights on it, paint it and call it good.

I'm just dreading all the finish grinding I have to do :?

 

[cruiseroutfit]

Wow, excellent solid modeling & fab skills... good work

However, I have to say it... what is your time worth per hour A smart shopper can find the bumpers for ~$700, after steel and powdercoat you have to be $300-$400, and that doesn't equate any of your time.

That being said I do it all the time myself... "why buy something for $200 that I can build myself for $300"

I'm excited to see the end result!

 

[Clay]

Sometimes, just the fact that you CAN do it is all the excuse that you need.

Looks good.

 

[stomperxj]

Wow, excellent solid modeling & fab skills... good work

However, I have to say it... what is your time worth per hour A smart shopper can find the bumpers for ~$700, after steel and powdercoat you have to be $300-$400, and that doesn't equate any of your time.

That being said I do it all the time myself... "why buy something for $200 that I can build myself for $300"

I'm excited to see the end result!

Thanks for the nice comments... Yeah I do think about what my time is worth while building stuff. Sometimes it is more cost effective to just go buy something but in this case I could probably build 3 of these for the cost of one real ARB... the steel isnt going to be much over $100. I bought all scrap pieces at the local yard for 30 cents/pound. My time is free when I'm doing stuff for myself Plus like Clay said, when someone asks where I bought the bumper I can say that I built it...
:iagree:

 

[ntsqd]

I, too, sort of copied the ARB design.

The four holes in the lower angled surface are for the bolts that pick up the stock bumper mount points on the frame.

Note the 3/4" thick shackle lugs. They're excellent for wonking me on the head as I'm climbing out from under the truck.

The sheared & bent steel set me back about $200 in '96, but it made for very little contour grinding. The body is 10 ga. and the inner frame and winch mount floor are 1/4"
I've been contemplating making a new one sans the winch pocket. I've had the winch for ~5 years and it has yet to be mounted or even looked at. New one would go to using a receiver socket winch mount.

"why buy something for $200 that I can build myself for $300"

Hey! Quit hanging out in my head!

 

[BigAl]

...



...I'm just dreading all the finish grinding I have to do :?

Nice work! Are you doing any kind of recovery points? The welds look good, just skip the grinding

 

[The BN Guy]

Very nice looking bumper!

 

[stomperxj]

Nice work! Are you doing any kind of recovery points? The welds look good, just skip the grinding

Yes recovery points are going to penetrate the front side somewhere. I'm just going to extend the frame brackets out thru the bumper...

 

[stomperxj]

Update:

Well i did some tube work this weekend and got all the frame tie ins welded up. I should be able to finish welding/grinding and paint next weekend...

I love my roof rack too. 21 feet of pipe up there :

 

[Willman]

Very nice!!!

This has to be one of the cleanest jobs i have ever seen on somebody copying ARB!

 

[stomperxj]

DONE! I need to get some mag lite clips and a license plate frame so i can mount the plate but other than that, its done!


I was re-wiring the remote plug harness and found the most interesting thing of the weekend. This was under the protective sheathing of the harness:

I removed the solenoid from the factory box and mounted it next to the winch under the bumper:

The remote plug is tucked up next to the pass. side upright:

All done!!

 

[kcowyo]

Outstanding job - :clapsmile

You throw on an ARB sticker and no one would know the difference.

 

[WJinTRSC]

WOW!!!!!! That final Pic looks AWESOME!!! GOOD JOB!!! I bet no one will ever know!! Great job, and you'll appreciate that one a lot more than you ever would the ARB. ENJOY!

 

[stomperxj]

Thanks for the nice comments guys. I'm pretty happy with the result myself. I just need to go tension the cable and then go pull somtething ... :wings:

 

[toyrunner95]

holy crap! thats amazing! ARB might even fix it if you send it back bent HAHAHAHA! nice job!