Phase II of the rear bumper design is well under way.  In fact, it's mostly done I think.

So, after getting all the good feedback on the first pass of the rear bumper design, I've gone through a bit of a re-design phase.  Most of it isn't that noticable.  Here is a summary of the changes I've made.

1)  Reduced thickness of rear bumper from 1/4" to 3/16".  This was based on feedback from others that 1/4" was overkill.  Plus, it wouldn't allow for much give in the case of an accident and might even cause frame damage.  On the plus side, going thinner reduces weight.

2)  Added hooks for safety chains when towing.  Kind of forgot this on the inital design.  Good catch everyone.

3)  I decided to move the hitch pin placement in front of the bumper instead of behind it as I had originally planned on.  I think it makes for a better looking bumper anyway.  Especially with the hooks for safety chains below it.

4)  Shackles will go all the way through the bumper and be welded to both the front and rear walls.  This will significantly add to the strength should I need to use the shackles for their intended purpose.  Plus, it makes the welds easier.

5)  Not shown, but I am going to add crush sleeves where the frame support brackets attach to the frame.  Better to replace some sleeves than to damage the frame.

That's it for the changes.  For additions, I've gone ahead an added the tire carrier I've been working on.  I still need to put the placement for the jack on it.  I think this will lay across the bottom of the supports.  Probably with some studs/wing nuts coming off of the side angles.  This is going to be an as-built modification. 

I also need to figure out the latching mechanism.  This will be added once I figure it out.

If you have any comments/suggestions, please leave them below.

Download the solidworks file of the in progress bumper here

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Comments (3)

1. Written by Rookie130, on 05-06-2007 12:02 Try this from McMaster-carr (5135A230). Mount it at a 45 deg angle to clamp it tight in the YZ plane.    Are you able to share your solidworks parts? I have started a similar bumper in solidworks, but I don't have all of the mounting dimensions. Did you take the dimensions from your Jeep?    Also, what are the specs on crush brackets? The name makes their use self-explanatory, but do you have more specifics?

2. Written by tjanssen, on 05-06-2007 13:04 Originally I was going to go with a sort of spring loaded pin locking mechanism on the rear bumper, but after talking to another guy designing his own rear bumper, and after your suggestion, I think I'm going to go with something like you suggested. Plus, I think eventually, the rattling would drive me nuts if I did the spring loaded idea.    As for the crush sleeves... It was suggested to just add a piece of tube/pipe that had an OD the size of the holes in the frame that was the length of the frame width. Then the bolt would go through the center of the tube. That way if any damage was done, it would be easy to just replace the sleeve. I haven't really looked in detail at it.    Dimensions...I haven't gotten around to measuring the frame yet for the mounting dimensions. But, my assembly makes it easy to move the mounting system to match. The only thing that is measure are the mounting holes on the channels that attach to the rear of the bumper. I actually pulled them from a Warn rear bumper installation guide.     And I'll post the Solidworks parts in a zip file on this page.    Thanks for the latch suggestion!

3. Written by rookie130, on 14-06-2007 10:27 Here's a lockable alternative...    http://www.toolfastclamps.com/toggle9.html#one

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