Boiler's Rear Bumper Build - Prototype #1 installed pg 4

Boiler · **Posted:** Sun Apr 04, 2010 5:10 pm

Progress is being made, just not as fast as we hoped. Doing a couple drawings and then heading back to the shop to continue. I've got a swing out arm tacked, bumper body welded, sides of the bumper and mounts tacked to it.

One thing we've found is that the way we've done it is waaaay too expensive. We're going to have to trim some fat before we can set a price.

Some pictures in the next few days probably.

VoodooMann · **Posted:** Sun Apr 04, 2010 7:58 pm

foglebr · **Joined:** Sun Feb 14, 2010 4:38 am **Posts:** 23

I'd love to see some photos or cad sketches of the rear bumper design. After Rock Lizard quit I was afraid I would never be able to get my Jerry Can capable rear bumper!! Thanks a ton for getting this product started, and soon off the ground. :SOMBRERO:

Boiler · **Posted:** Sun Apr 04, 2010 11:24 pm

I should have just shut up until I was done. We were trying to get the first prototype done for tomorrow to send to powdercoat 1st thing tuesday, installed wednesday. Not much room for error but it has taken every minute possible just to get a shot at getting it done in time.

Well we ran into a couple demons today with the frame mounts, and the fact that my swing arm touched the tailgate. :roll:

Some changes coming to the swing arm this week obviously, and we'll probably finish the main bumper this weekend. But I'm finished working on it 24/7. Our goal is to have it completely finished in three weeks, including powdercoat and install. (our customer is unavailable for next two weekends). We're going to push through and get it done asap still, but I did lay on my couch and watch a movie tonight, for the first time in what seems like an eternity.

I'll have Tony take some pictures next time the bumper is on, probably around midweek.

dgeist · **Posted:** Wed Apr 14, 2010 5:01 pm

10 days of idle. Hoping for a Polaroid ....

KJ 119 · **Posted:** Wed Apr 14, 2010 5:21 pm

Yea Boiler,you laying on our leg or what?
I'd be happy to see a pic of a pile of metal and a Miller.

Wussuuuuup :juggle:

tommudd · **Posted:** Wed Apr 14, 2010 5:21 pm

When I spoke to Boiler on the phone a couple of days ago he was standing in front of a mirror trying to find a few more strands of hair to pull out.
Might be a day or two more yet before any pictures are up!
:lol:

Boiler · **Posted:** Wed Apr 14, 2010 6:06 pm

or ten.

I'm laughing at myself now, I was once such an optimistic young lad...

Anyway, Tony is out all week this week so we are stopped until next week. going to try to finish it in the next couple weeks. Our deadline got missed so now we're working our normal hours, not the psycho ones we were doing last month...Soon though, I'm tired of having a naked rear on the KJ.

tommudd · **Posted:** Wed Apr 14, 2010 6:19 pm

You've learned a lot in a short time Grasshopper :wink:

DoverKJ · **Posted:** Sun May 09, 2010 10:43 am

Any progress?

Boiler · **Posted:** Sun May 09, 2010 3:46 pm

Yeah, slowly...

We made tons of progress the first few weeks after posting that, got the bumper all tacked up and fit, tacked up the swing arm...but we didn't get it done by the hopeful deadline, and then basically we both had a million committments, so now we're back at it hard and trying to get it completely done by the end of the month.

tonycrd · **Posted:** Mon May 10, 2010 2:07 pm

Boiler wrote:

Quicksilversurf917 wrote:

So this is going to be a bumper.....?

Yep. 1/4" thick aluminum bumper, with options for hitch receiver, imbedded rear foglights, swing out tire carrier, jerry can holder, & hi-lift holder.

Cool!!!! We need pics ASAP!!!

Boiler · **Posted:** Sat May 15, 2010 1:35 pm

Well, we had it on my jeep today to do some work on the swing arm (not shown). Here is what we've got so far for the bumper. Please not that there is plenty of welding and grinding to be done to make it pretty yet.

To answer a few questions before you ask: Nope, I don't know what it costs yet. Alot. If it looks like it needs welded, ground, brushed, it will be. The reciever tube is 1/2" thick, light bezels are 1", 3/8 x 3 angle mounts with 1/2" stiffners, 1/2" backers welded to the mounts and bumper skin where the shackles get attached, 1/4" pretty much everywhere else. Shackle tabs are 1" thick and go at the "13-1/2" sharpie drawn dimension shown in one of the pictures. The spindle can be screwed out. It is a steel spindle that has been threaded and drilled at the bottom. It screws into a female threaded 2" x 1/2" wall tube that is down in the bumper. There is a bolt in there too to keep them from turning once it is screwed in. The 2" tube will get ground out and welded on top, so you won't see the seam.

If you're debating getting one someday already, I'd wait before passing judgement or falling in love with anything. I've got to get some cost out of this thing or the pricetag will be insane. So some things will change slightly, but this is basically the idea and the rest will look close enough to this to show it.

If you think anything looks weird or built poorly, just assume it is an optical illusion.

kskj · **Posted:** Sat May 15, 2010 1:55 pm

Nice work Boiler, Thats the best looking rear bumper I've seen.

DoverKJ · **Posted:** Sat May 15, 2010 1:57 pm

Looks good.

tommudd · **Posted:** Sat May 15, 2010 1:58 pm

Boiler

OK for the negatives
I'll find something..... :wink:

will the angles stay the same at the top near the tail lights, more rounded would blend in better with the body and rest of the bumper, just a suggestion :wink:

Ok now for the positives
Looks great, over all design is good, flows pretty good with the body lines
I know you've put a ton of hours and thought into this and it shows.
Overall Good job

Now build a cheaper version in "steel" :pepper:

Boiler · **Posted:** Sat May 15, 2010 2:20 pm

tommudd wrote:

Boiler

OK for the negatives
I'll find something..... :wink:

will the angles stay the same at the top near the tail lights, more rounded would blend in better with the body and rest of the bumper, just a suggestion :wink:

Ok now for the positives
Looks great, over all design is good, flows pretty good with the body lines
I know you've put a ton of hours and thought into this and it shows.
Overall Good job

Now build a cheaper version in "steel" :pepper:

Do you mean the sharp corners? Pretty much everything will get ground to have about a 3/16 to 1/4' radius.

As for making one in steel: The material would be cheaper, and it would be easier for us to weld (less prep by a longshot) but right now the killer is machining and waterjet cutting. I'm into those guys for about $700 alone on this bumper, not including material, purchased parts, and our blood, sweat, and tears. I need to get their cost down to about $250 and then I think I can make this feasible to produce. It can be done!

JustinP · **Posted:** Sat May 15, 2010 2:41 pm

I really like it, I usually dont like custom bumpers but I'm digging this one, I can't wait to see it finished and with the flares back on. Good job, I hope you can get the price of production down enough to be affordable. Cant wait for more progress.

tommudd · **Posted:** Sat May 15, 2010 2:49 pm

Hey Boiler send me the patterns, I just got some new hacksaw blades and I'll cut one out and Tony can weld it up if that will help! :ROTFL:

VoodooMann · **Posted:** Sat May 15, 2010 3:10 pm

is it just me, or is that box hiding something?

looks awesome BTW.

I might want one

Boiler's Rear Bumper Build - Prototype #1 installed pg 4

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