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Default Warn Bumper Rebuild -
by Detour 08-15-2009, 04:44 PM

A good friend of mine recently purchased an '04 Rubicon, on it's rear was a pretty tired looking Warn bumper, the design is nice enough.....but it's powder coating was failing and it did'nt have the options the owner wanted.

This is a follow along "How-to" artical showing how Detours will convert this basic bumper into a bumper with a swing out carrier, real recovery points and a new finish.

First off, the bumper......it's the basic Warn, rusty & in need of a face lift.








Typically, when reworking older parts I like to start by sandblasting them clean, we will be doing so shortly, but first I figured I locate the area for the hinge pin which will support the swing out carrier.



The hinge pin assembly will be the same we use on other carrier systems, we have this item made for us locally, a 1" hole will be required in the bumper for the pin to drop through, for this job I chose to use our magnetic drill, it will provide a true 1" hole.



Simple enough with the correct tools, the hinge pin assembly drop right into place, zero slop between the pin and in new hole it calls home.



Next, we'll be sandblasting the old powder coating off and continuing to cut this bumper open to secure the hinge pin and create recovery points.

Stay tuned!
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  #2  
Old 08-15-2009
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Cool, thanks! This should be interesting.
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Old 08-16-2009
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I'm interested, thanks!!
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Old 08-18-2009
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Detours is producing some magic again. I can't wait to see what he pulls off with this bumper.
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Old 08-19-2009
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Alrighty then.......it's hard for any item to hide it's 'hide' while being sandblasted, this bumper proved no different. It appears it's already had a face lift in it's life, we exposed actual paint, etching primer, bondo and previously existing powder coat.........the rust factor is/was multilayer exposing the red rust......red rust is the worst, it dosent die..............We're going to handle this by a decent 90% blast, do what we need to do.....follow up with a final blast then move it directly into the paint mode minutes later....

So, here we go.....the first blast.....





Alright, so that done, it's time to do the layout work for the recovery, recovery points will be 3/4" thick by 3" bar stock.......







I layed out the recovery point on the hinge barrel side of bumper directly beside the hinge barrel, it will serve double duty as I will be welding the base of the pin to the recovery point. The other side or drivers side gets the same layout, time now to break out the plasma cutter....



Test fit.......



Moving on.....



I opened up the backside on the hinge barrel side, keep the removed part for later, by opening the area up we'll be able to get in there to weld and secure the new parts...



On the passenger side, I simply drilled 7/16" holes to secure the back side of the recovery point, being a flush fit (to the rear crossmember) bumper, I did'nt want to open a can of worms leading to alot of grinding, if you're confident in your abilities as a welder......multible plug or rosset welds will no doubt secure the backside of the new recovery point.



Moving forward, I then positioned and squared the tire carrier hinge barrel and fully welded it to the new recovery point, the underside base of the bumper, and the opposing face of the bumper..........it's pretty much there for the rest of its life lets say.........



Recovery was also fully welded....view from the top -



So now, lets go back and make some repairs.........the part removed inorder to weld in the hinge barrel, clean it up and position it flat with a magnet or some flat stock.......



Give 'er the full weld treatment....



Then show it some love and give 'er a full grind treatment so it sit properly against the TJ's rear cross member again.....



Stay tuned!
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Old 08-20-2009
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Nice, you make it look so easy!
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Old 08-20-2009
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You are going to replace those "W"s with "D" right?
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Old 08-20-2009
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Quote:
Originally Posted by Mudderoy View Post
You are going to replace those "W"s with "D" right?
We joked about it, but the 'W' allows access to the bolts holding it to the crossmember, I dont think a 'D' would allow this.......but ya, we discussed it.
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Old 08-20-2009
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Nice work!
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Old 08-21-2009
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Thanks....more latter today......unless I decide to go drop a few trees later.....
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