Project bumper recycle!

[Gojeep]

Project recycled bumper

Well I feel I'm doing my bit for the environment and recycling some ARB bars ;)

Just started and have some progress shots.

http://go.jeep-xj.info/ARBbar001.jpg

Well here is 2 of the 3 bars I have to work with. All 3 bars are to fit a 80 series Landcruiser which I like the shape of the most and what I made my rear bumper from already.

http://go.jeep-xj.info/ARBbar002.jpg

Well didn't take long to rip the first one apart. I only needed the one end from this to replaced a badly twisted one on the third bar I have. Cant see in the shots but this had the mounts bent across at about a 40 degree angle which had buckled the centre section. Looks like I wont need any parts from the white winch one at all. This one looks as though it has been just knocked back on one side a bit but was very hard to tell until I put a straight edge on it. Might make a good project for someone who wants a winch mount which I didn't.

http://go.jeep-xj.info/ARBbar003.jpg

You can see here how I have filled in the old indicator hole. Not needed as I wont have the top bars interfering with the stock ones. I panel beated the damage it had and now it is nice and square too.

http://go.jeep-xj.info/ARBbar004.jpg

This is the third bar which only had the end damaged on it.

http://go.jeep-xj.info/ARBbar005.jpg

Not much left of it now!

http://go.jeep-xj.info/ARBbar006.jpg

Just laid it out after filling in the other indicator hole but much still to do as is way too wide for the Jeep and I want to change some angles yet plus the new mounts and a few other things.

Hope to get more done tomorrow. ;)

[taziiy]

How did you come across so many bars

[BLU-125]

There's one on most corners in country towns ;D ;D

[Mad Cruiser]

You could give the white 80 series bullbar to me, a poor student ;)

[Sim79]

I have been thinking about doing the same it will work out $1000s cheaper than buying a rear bumber and it looks heaps beter already. Can't wait to see it fitted. Now I have to find some bars to chop up!

[Gojeep]

I have been thinking about doing the same it will work out $1000s cheaper than buying a rear bumber and it looks heaps beter already. Can't wait to see it fitted. Now I have to find some bars to chop up!

Take a look at my site and you will see the rear bar I made from another 80 series bar too.
Took me over a year to collect the bars so they are hard to come by for me too.

[Sim79]

Take a look at my site and you will see the rear bar I made from another 80 series bar too.
Took me over a year to collect the bars so they are hard to come by for me too.


Just checked your site nice Jeep. You did a great job on that rear bar hope mine turns out like that. Thanks for the info

[Gojeep]

Today's effort below. Didn't get as much done to look at as there was a lot of trimming a bit, trying it, trimming a bit more and so on. Also had to help quite a few other people out that dropped by needing welding done!

http://go.jeep-xj.info/ARBbar007.jpg

This is a rear Hayman Reese hitch and step off a Rodeo that I picked up. I am going to use this as part of my bumper.

http://go.jeep-xj.info/ARBbar008.jpg

Wont be using too much of it as you can see.

http://go.jeep-xj.info/ARBbar009.jpg

The other bumper has been taken off ready for the next step.

http://go.jeep-xj.info/ARBbar010.jpg

You can see how I incorporated the hitch in my old bar that I made from a Landcruiser Prado ARB bullbar. Notice how I had a bar operate the hitch pin from under the guard.

http://go.jeep-xj.info/ARBbar011.jpg

View from the front showing how the number plate kept the receiver hidden.

http://go.jeep-xj.info/ARBbar012.jpg

Some test fitting to see how it looks.

http://go.jeep-xj.info/ARBbar013.jpg

http://go.jeep-xj.info/ARBbar014.jpg

Just deciding on the rake of the front. Need to leave enough for protection but still not hinder the approach angle. Might still tuck the corner back a little more. Here it is sitting at 40 mm at the corner with the centre section at 60 mm projection. Don't want it too flat either as want to protect the radiator.

[smac]

great idea mate. Looks good too. i reckon you should 'chrome' it so it blends in with your grille etc - would look pretty good i think.

[Mad Cruiser]

GoJeep...

How much did u pick up those bullbars for ?

So i have a good idea of how much the wreckers will be charging, if it's too high or a bargain etc ;)

i like what i see!!!

[boof]

looks good something a bit different

[Gojeep]

Thanks for the comments guys and taking an interest in the build up. ;) I did not get much done today as only had some of the afternoon free. It is also getting down to the time where much time is spent but not a lot to show!

http://go.jeep-xj.info/ARBbar015.jpg

Did more work on the hitch that is going to be fitted. I cut off what is going to be the front face as the front of the bumper will be replacing this so no need to double up. You might noticed that a section on the middle is cut back a bit further. This will be plated and sit behind a cut out in the bumper face. Will make more sense later.

http://go.jeep-xj.info/ARBbar016.jpg

I did also get the mounts finished out of 1/4" plate. They are the same design as the factory tow hooks. I dont like to incorporate the steering bolts as dont want those sheared off if a hit a Roo! Also I am under 33" tall tyres and have a steering box brace.

[Gojeep]

GoJeep...

How much did u pick up those bullbars for ?

So i have a good idea of how much the wreckers will be charging, if it's too high or a bargain etc ;)


I dont buy them from the wreakers but an insurance assessor place. It is where panel beaters send bars to see if they can be repaired or not. They dont deal with the public however. Price will vary according to the condition of them. Ones sold in the past have been in the $200-$300 range that were in pretty good nick non winch ones but still need paint etc. Some badly damaged ones where I only needed a piece off them I can get for a slab of beer. You can make me an offer on the white one if you like if in my state or anyone else wanting it. I also have a hayman reese towbar to suit a landcruiser of anyone is interested.

[Gojeep]

Update from today's effort.
Started by sanding off most of the power coat so I was sure to get everything flush and square when fitting the side pieces.

http://go.jeep-xj.info/ARBbar017.jpg

Once I had finally settled on the angle I wanted, the fun was getting it tacked exactly flush and at the right height and angle. As this angle is less then what was before I have the fun of cutting little wedges to fill in the gaps.

http://go.jeep-xj.info/ARBbar018.jpg

I fully weld it by either leaving around a 2 mm gap or running the cut off wheel down it to get full penetration. Even though the weld comes through to the other side, I still place a cover weld over the join on the inside which is not ground back like the front face to give added strength ( will be stronger at the weld than the surrounding metal ).

http://go.jeep-xj.info/ARBbar019.jpg

It is not just the top that needs doing as I have had to add the wedges underneath as well. Here it shows one piece welded in and ground back before the next piece is added above it.

http://go.jeep-xj.info/ARBbar020.jpg

The top piece added and then the final weld to the joining plate put down.

http://go.jeep-xj.info/ARBbar021.jpg

Here you can see the test fit and the final angle finished for that join only. The corner will be the next altered as it will be pulled across tighter and the bar slid across so more protection is given around the side while still ending up flush with the flare.

http://go.jeep-xj.info/ARBbar022.jpg

Here you can see too how much has to be cut from the overall length as goes much further along the grille than the nearly finished side.

[boof]

that is looking awesome cant wait to see it finished

[Gojeep]

Thanks mate. ;)

As they say, it is the details that can make or break a project. So here are some that has taken up my time today.

http://go.jeep-xj.info/ARBbar023.jpg

To pull the end around tighter I had to cut along the radius and all the way down the join along the bottom. A wedge is then cut out along the top face to the degrees I needed to increase the corner by.

http://go.jeep-xj.info/ARBbar024.jpg

Once that is done I pulled the end around and tacked it in its new position. I then cut another wedge out so I could tuck the side across to follow the angle of the flare.

http://go.jeep-xj.info/ARBbar025.jpg

This gives you a view of new side angle and radius to the corner as well.

http://go.jeep-xj.info/ARBbar026.jpg

Another view where you can see that the same amount of protection at the start of the corner indicator as well as the end around the side.

http://go.jeep-xj.info/ARBbar027.jpg

The next fold I am making is to follow the side of the flare around the corner. To do this without cutting it right off, I cut through the top and bottom folds and then scored a line with the cut off wheel where I wanted it to fold. This is then welded back over on the inside.

http://go.jeep-xj.info/ARBbar028.jpg

http://go.jeep-xj.info/ARBbar029.jpg

Here you can see that it is pulled around ready for the excess to be cut off which will have to wait until tomorrow now.

[crack]

thats looking wikid mate!! cant wait to see it finished itll look good. like some said earlier you should chrome it. if only i could weld that well
jack

[PJ.zook]

Its not how you weld, its how well you angle grind! ;D ;D

[Gojeep]

Not going to chrome it as there is enough there already and any more would look tacky.
As for the welding comment, you must be a good welder if you don't wont it to fall apart later on! Good angle grinder work will never be a substitute for welds with the right penetration and strength. I have done work for the Air force and many factories around my area are also held up by my welding so no short cuts there ever!

[Boxa]

Great costum job. I like the personalised touch of maintaining the cars contours.
Waiting for the end result.
S

[Bundy_Harry]

Do you mind if I ask what type of welder you are using, is it TIG or MIG?

thanx

harry

[Gojeep]

Do you mind if I ask what type of welder you are using, is it TIG or MIG?

thanx

harry



All been done with a 3 phase mig for a nice stable arc. ;)

[Gojeep]

Thanks for the comments guys too :)
Well got a bit done this afternoon between rain showers and having to pull the harmonic balancer as noticed one of the timing cover bolts had rattled out and was stuck behind it! First bolt to do so after over a 100,000 Outback kms not including around town mileage.
No new photos though as I just duplicated everything that I did to the RHS piece to the left ready to weld in place. Tomorrow will be my last day for a couple of months that I can work on it as leaving for holidays to the Middle East ( Turkey, Syria, Jordan Lebanon and Egypt ) at the end of next week.
Remember too that my last custom bar is ready for sale for $690 to anyone that wants it including the number plate mount and recovery hitch. See my site for the write up ( http://go.jeep-xj.info/HowtoARBnew6.htm ) or there are plenty of shots of it when it featured in the magazine write up. ( http://go.jeep-xj.info/4wdMonthly.htm )

[Gojeep]

Last update for a couple of months.

http://go.jeep-xj.info/ARBbar030.jpg

Well it is finally one piece again but a little too wide don't you think? ;)

http://go.jeep-xj.info/ARBbar031.jpg

Here it shows just how much wider a Landcruiser 80 series is! No wonder I don't get many scratches after they have been through :laugh3:

http://go.jeep-xj.info/ARBbar032.jpg

I have started to cut it back up again so it was not in one piece for long. I have to cut out 8" to get the right width. The lower section is cut in different sections so the centre support can be kept after it is all put back together.

http://go.jeep-xj.info/ARBbar033.jpg

There are lot of pieces again to go back as one!

http://go.jeep-xj.info/ARBbar034.jpg

Just tacked the upper section together to check to see if my measurements were correct. It was 1.5 mm out so pulled it apart again to get it perfect.

http://go.jeep-xj.info/ARBbar035.jpg

Well here it is one piece again and was getting too dark to do anymore. I have also stress relieved the welds to remove any distortion and is now nice and flat.
My intention is to add a power steering cooler above the vents for extra cooling for the high temperatures I get when crossing deserts and beach running.
Well finally you can get a picture that I have only had in my head up until now of what the final result will look like. ;)

[RED60]

Bar on a budget, I like it. If ya haven't got the $ make up for it with effort. How thick is the material you're workin' with, looks about 2.5/3mm. Well done Go.

[Gojeep]

Well survived our 2 month Middle East overlanding tour and if you want to see some pictures that I put up for those with us see here. http://go.jeep-xj.info/MiddleEastShots1.htm ( 8 bombs did go off in places we had already left while there though! ).
Have had a chance to start work on the bar again so here is some progress shots.

http://go.jeep-xj.info/ARBbar036.jpg

So here is the bar as I left it positioned on the Jeep for the first time since shortening it to the right length. Not sure about the two small vents in the lower front as it makes the centre section look too narrow and would cut down the air flow over the cooler?

http://go.jeep-xj.info/ARBbar037.jpg

I noticed there was some twist in it ( as you can see before I straightened it ) from the welding so I welded on some pipe to get the leverage needed and then pulled it back perfectly straight.

http://go.jeep-xj.info/ARBbar038.jpg

I decided to cut out the vents right back down the welded joins from before and replaced it with a single piece from one of the other bars. I think it looks better this way now. Spent a lot of time panel beating it to get rid of any distortion left from the welding and to de-stress the joins.

http://go.jeep-xj.info/ARBbar039.jpg

So here it is for the first time tacked to the chassis brackets I had made earlier. I bolted them up first with some card behind them to space it out I bit so it is not too hard to place it back again later after it has been painted. Tacking it on the Jeep also allows perfect placement which I managed to get to less than 0.5 mm left to right and forward and back.

[Gojeep]

Bar on a budget, I like it. If ya haven't got the $ make up for it with effort. How thick is the material you're workin' with, looks about 2.5/3mm. Well done Go.


It is all in 3 mm which is what ARB uses for their 80 series bars.

[cpt-mud]

looks really good

[boof]

that is looking awesome wish i had those skills :'(

[Gojeep]

Just a little update.

http://go.jeep-xj.info/ARBbar040.jpg

Here you can see the frame brackets welded in place

http://go.jeep-xj.info/ARBbar041.jpg

The next part of the project is adding the Hayman Reese towbar for my recovery point. Starts by cutting out a section from the front of the bar.

http://go.jeep-xj.info/ARBbar042.jpg

That done, the welds where the towbar will sit are ground and the bar plates are notched to take the towbar.

http://go.jeep-xj.info/ARBbar043.jpg

This shows the towbar with some plates welded in place to sit behind the hole cut in the bumper. This will make a little more sense if you look here at my old bar. http://go.jeep-xj.info/HowtoARBnew5.htm

http://go.jeep-xj.info/ARBbar044.jpg

Here you see I have also added some more steel to the inside corner for more strength and made up some end caps to finish that part off.

[taziiy]

very impressive i like what your done

[brooksy]

Nice work GOJEEP,
Any reason for not building bar to accomidate a winch or is your approach angle your main worry. Must have friends who can winch you out maybe ??

brooksy

[Gojeep]

I have been 4wding for over 12 years now and really know what I can and cannot get through. A winch is very rarely used by me and I have a good hand winch to do the job when I need to. So I see no point in carrying all that extra weight and reduction in approach angle, as you suggest, for the rest of the time. It also causes more tyre and suspension wear plus a reduction in handling. If I was still a weekend warrior it might be different but only do long range touring every year now.

[TOY80ST]

Out of curiosity how long has this taken you so far??
P.

[Gojeep]

Not sure as I never get to work a full day on it. If you count my posts you have a fair idea as I post a days work each time which is around 4 hours.

[taziiy]

well the thred started on the 1st of june so 2 months on and off so far i would say

[Gojeep]

well the thred started on the 1st of june so 2 months on and off so far i would say



I have 8 posts there but I remember 1 or 2 days where I just repeated what I had done to one side already so did not take shots on that day. I do around 4-5 hours a day so have 40-50 hours invested in it so far. Just as well it is a labour I enjoy and is free time as paying an hourly rate would kill it. I could make it faster if I still had access to a brake press and plasma cutter but don't any more.
You can see why though I cannot make another for someone and even if you look at the one I had on there, which took nearly as long, how it does not pay. I have not even sold that one yet for $600 which doesn't come close to paying for my time let alone the cost of the bars to start with and the professional spray job I paid for!

[TOY80ST]

I know what you mean about the brake press. I used to have access to one and I made my entire bullbar in 8hours not including painting and the only thing I didn't do was bend the pipes, I had the exhaust bloke do that for me. I have found an oxy with a size 6 tip ok for cutting 3mm+ steel.


http://tinypic.com/bgahi0.jpg

I know what you are going through doing that enjoy.
P.

[Gojeep]

Good job too and that bar there mate. ;)

[TOY80ST]

Believe it or not but that bar started out a recyled one too, I cut an old bent bar apart and then decided it was going to be too hard to repair and wouldn't take my high mount, so I made a complete newie. The only original bit from the TJM unit is the arial mount for the UHF. and one of the driving light mounts. You've done great with your's though. If you ever see any of my work just remember that I am a design engineer(mechanical) and I was a boilermaker for 13 years before that. and I have a lot of resources to call on, like design software and welding and cutting equipment I have gained through the years.
I have two projects on the go at the moment 1 is a rear wheel carrier and the other is a dual axle version of the ultimate camper (cross between the coota camper and the ultimate). I have finished the design for the rear wheel carrier and I will start to build them soon (3x mates too).
The trailer is still a long way off having the design finished (have a look at my diy ultimate on the third or fourth page at the top) the trailer has been like that for 9 months now it is registered as a box so I am getting use out of it.
Anyway once again good work keep it up,

P.
ps. Sorry to babble on a bit

[Gojeep]

He he, that is not a lot to use from a whole bar. I think you can safely say it is all your work. ;)
I remember your trailer if it is the one with the horizontal coil spring. I like hearing from others with projects as you can always learn more.

Cheers.

[Gojeep]

Not a lot of progress this week but got a few days worth in.

http://go.jeep-xj.info/ARBbar045.jpg

Just got to fitting in the Hayman Reese towbar into the bumper.

http://go.jeep-xj.info/ARBbar048.jpg

It is also fully welded around the front opening in the bar as well as to the chassis and joining plates in the back.

http://go.jeep-xj.info/ARBbar046.jpg

A hitch pin is cut just before the bend and welded onto a pipe. A support bracket is also there to hold it up when fully retracted and will be positioned so it can not be pulled out too far.

http://go.jeep-xj.info/ARBbar047.jpg

This shows how it is retained when in the closed position. A large thumb screw goes through the tag into a threaded hole in the chassis bracket.

http://go.jeep-xj.info/ARBbar049.jpg

You can see the new chassis re-enforcement bracket made to be supplied with the old bar when it is sold as I leave mine in place. Also the beginnings of the new number plate holder that slots into the Hayman Reese being readied.

http://go.jeep-xj.info/ARBbar050.jpg

This is a new shackle mount to replace the one made for the old bumper which goes with it.

http://go.jeep-xj.info/ARBbar051.jpg

Here showing it fitted into the bumper.

[Gojeep]

Just a small update on the progress on the bumper.

http://go.jeep-xj.info/ARBbar052.jpg

Just showing the mounting of a stock Cherokee transmission cooler to be used as a power steering cooler. I didn't set out to fit this in particular but it just worked out that way in the end. Couldn't find anything else to fit as well.

http://go.jeep-xj.info/ARBbar053.jpg

You can see here how well protected it will be. I will still add though some expended mesh in front of it to protect it against stones.

http://go.jeep-xj.info/ARBbar054.jpg

Final fit up before I panel beat out any little dents and dips and sanded it all flat ready for painting.

http://go.jeep-xj.info/ARBbar055.jpg

In the back ready to go off for it's last stage. I painted the inside quickly just to keep the cost down for the final painting to be done by a painting shop. Will be done in 2 Pac in a semi gloss black. They were impressed with the job and said I had way more patience then they. Now that's got me worried they wont do a good job on the bumper!

[brooksy]

Once again ,

Very Nice Work !!

I am going to be helping out an after market L/Rover specialist who builds" custom everything " to do with 4wd's. In return I will be getting his designed custom front bar, R/sliders & we are designing a rear bar at the moment. I have 17 yrs in the Metal industry - Fitter/turner, 1st class Welder. I have been out of the industry for 2 yrs but he asked if I would be interested in giving him a hand when I had spare days. The wife said OK as it will save us sh*tloads in aftermarket bar work so I'm going in with my tools next weekend !!

brooksy

[Gojeep]

Sounds like a bit of fun and I enjoy working on things like this. Always good to have an arrangement like that as I have to. I did all this at a truck repair place for free in return I do any welding jobs that come in while I'm there.

[Gojeep]

Just took a few shots a couple of days ago of my bar at the painters. It has been further sanded and he has sprayed 3 coats of 2 pac primer which is thicker than normal primers. He said that is all that was needed to remove the marks left from the grinding and hammering I did to get it all nice and straight. He was next going to skim coat and block it, which is where they spray a very light coat of black over it so they know where they have sanded and any low points show up, before top coating it in 2 pac satin black. The bar was to be ready for pick up on Friday but I hadn't got my radiator back and was in the middle of installing an over head console in my Jeep so couldn't drive out to pick it up. Probably best anyway as gives it a bit more time to harden before fitting it.

http://go.jeep-xj.info/ARBbar057.jpg

http://go.jeep-xj.info/ARBbar058.jpg

http://go.jeep-xj.info/ARBbar059.jpg

Next shots should be the finished bar and fitting it. ;)

[Gojeep]

Sorry for the delay on the finished photos but the weather has been really crap and I wanted to give it a cut and polish first. Not quite done with that yet and will take some more shots with my better camera next week.

http://go.jeep-xj.info/ARBbar060.jpg

http://go.jeep-xj.info/ARBbar061.jpg

As you can see not much sticking forward. Would be the same as a stock bumper.

http://go.jeep-xj.info/ARBbar062.jpg

The power steering cooler is all plumbed in now to after I bent up some mesh to go between the that and the bar. The lines were run to the return line which is not under pressure. I had already cut this line to add an inline filter to it so any wear particles don't keep circulating wearing things even faster.

A lot of work went into it but enjoyed doing most of it and happy with the end results.

I also just dropped the price on my former ARB bar with the same hitch setup in it to get it out of the way for $590 or $450 USD. to anyone who would like a piece of my work.

[taziiy]

I have 2 questions
1. how do you put the pin in when fitting the recovery hitch

2. how do you get it in there when the plate is covering the hole

[Gojeep]

I have 2 questions
1. how do you put the pin in when fitting the recovery hitch

2. how do you get it in there when the plate is covering the hole


Easy, look at reply #42 above. ;)

[taziiy]

oh ok nice thinking there

[Gojeep]

Here it is a bit clearer. I'll post it as you were not the only one that asked. ;)

http://go.jeep-xj.info/ARB%20099.jpg

Plate attaches to this plate that was cut out of the front of the bar in the first place. It has a 2" tube welded to it so it held in place by the extended hitch pin.

http://go.jeep-xj.info/ARB%20124.jpg
Here is is part of the way in.

[taziiy]

Ah now i get the picture ;D

[Gojeep]

I have taken these shots with my 7.1 meg camera rather than the 2 meg one I usually use for my work projects. You can see more detail now and where the extra megs really shine through.
Hope you like the end results and is the last front bar I make by choice for this as very happy with the results.

http://go.jeep-xj.info/ARBbar063.jpg

http://go.jeep-xj.info/ARBbar064.jpg
Just showing how the number plate is attached and covers the hitch hole

http://go.jeep-xj.info/ARBbar065.jpg
The shackle mount I made fitted.

http://go.jeep-xj.info/ARBbar066.jpg
This is how the extended hitch pin is held in place with the thumb screw. The gold paint is to make it easier for me the line up the hole when it is a bit dark.

http://go.jeep-xj.info/ARBbar067.jpg

http://go.jeep-xj.info/ARBbar068.jpg
I would say the approach angle is as good as a stock bumper.

http://go.jeep-xj.info/ARBbar069.jpg
Just a close up of the corner showing the extra bend put in for the flare and the tucked in angle to follow the flare profile.

[brooksy]

Love it mate except for the ARB sticker, I wouldn't have put it on.
Top quality work Gojeep !!!! 8)

brooksy

[RedGQ]

You could charge big bucks for wrok like that and make a nice living from it. But then again its fun making it for yourself, Making it for work is not quite the same.

[boof]

awesome job but i wouldnthave put the arb sticker on either but i guess itwill stop everyone asking where you got it should be some confused arb sales reps around soon ;D

[Gojeep]

Thanks guys for the comments. It is still an ARB in the 'bones' of it but I did it too that should I have an accident, an insurance assessor seeing an ARB sticker wont think twice about it and wonder if it is a home made job or not and if it is compatible with the airbag. That's why I have gone to great lengths to keep the crash pulse as similar as I could between the bumper and a ARB original. Any stiffness gained by fitting the Hayman Reese ( another reason I cut the front wall off the towbar before fitting it ) behind the bar was balanced out by the loss of the uprights and tubes that I cut off the top. Remembering that raising the crash pulse only makes the airbag go off at a lower speed and not at a higher speed as some seem to think!

[KUSTOM V840]

EXCELLENT WORK MATE!! LOOKS LIKE A FACTORY FIT! WELL DONE, YOU SHOULD BE PROUD!! ;D ;D

Sparra

[Gojeep]

Well thank you very much. :)

[mud masher]

awsome job mate looks great .