XJ rear box portion- necessary?

HULK · 12-28-2005, 08:36 AM

I am doing a fair amount of cutting on my heep, and am about to start on my rear bumper. I obviously want it to be as high clearance as possible. I would like to angle up the ends as much as possible, but these boxes are in the way. How necessary are they? I dont know what it does or what it is for. Can I trim it? Should I box it in with 1/4" once I am done trimming it? Or is it fine to just hack it off and leave it? THanks for the structural help....

deke · 12-28-2005, 08:38 AM

I'm working on trimming the same pieces right now. They are part of the tie in for the box around the upper shackle bolt like I'm sure you are well aware of. So we'll need to re-enforce the area to make up for the lack of box support

myjeepsbigger · 12-28-2005, 08:47 AM

You planning on a cage, HULK? Nice work so far. Ditto what deke said.

HULK · 12-28-2005, 08:56 AM

Yes, cage is next. So, what would you recommend doing to reinforce that area?

deke · 12-28-2005, 08:58 AM

Depends on how much you are cutting.

Look at the direction of the force with the body pushing down onto the spring. Find where you can distribute that load out to... and re-enforce. I wouldnt use anything over 3/16.

HULK · 12-28-2005, 09:10 AM

I was planning on cutting it like this.

SO, should I just plate that angle back in?

deke · 12-28-2005, 09:12 AM

Theres going to be 2-3 layers of steel there that are now just sitting next to each other. I'd weld that cut edge up the entire length. then put a piece of 3/16 on the backside and have some holes for plug welds

myjeepsbigger · 12-28-2005, 09:35 AM

One thing I did when I hacked out the rear side of mine, was to lay a piece of 4" c-channel in that area ("C" facing out). It was plug welded/stitched AND bolted to the body (bolted at bumper mounting area)....I attatched my rear bumper to the C-channel. REALLY tightened things up.

deke · 12-28-2005, 09:38 AM

Quote:

Originally Posted by myjeepsbigger

One thing I did when I hacked out the rear side of mine, was to lay a piece of 4" c-channel in that area ("C" facing out). It was plug welded/stitched AND bolted to the body (bolted at bumper mounting area)....I attatched my rear bumper to the C-channel. REALLY tightened things up.

Them body squeeks go down a lot

HULK · 12-28-2005, 09:54 AM

Quote:

Originally Posted by myjeepsbigger

One thing I did when I hacked out the rear side of mine, was to lay a piece of 4" c-channel in that area ("C" facing out). It was plug welded/stitched AND bolted to the body (bolted at bumper mounting area)....I attatched my rear bumper to the C-channel. REALLY tightened things up.

Im not sure I understand what youre saying. Got pics to help me?

IntrepidXJ · 12-28-2005, 10:06 AM

i did something similar to myjeepsbigger using a piece of 4" flat with a 1" piece of flat welded 90 degrees at the bottom for rigidity. This really helps stiffen up the rear crossmember.

can see it in this pic

I have not built a new rear bumper yet, but will tie them together when I do.

I had also considered cutting like you are thinking, but have not made up my mind yet....will continue watching this thread

98XJDMB · 12-28-2005, 12:35 PM

i can't help you, but damn thats a nice chop job

myjeepsbigger · 12-28-2005, 01:37 PM

Quote:

Originally Posted by IntrepidXJ

i did something similar to myjeepsbigger using a piece of 4" flat with a 1" piece of flat welded 90 degrees at the bottom for rigidity. This really helps stiffen up the rear crossmember.

can see it in this pic

I have not built a new rear bumper yet, but will tie them together when I do.

I had also considered cutting like you are thinking, but have not made up my mind yet....will continue watching this thread

Bingo. Just imagine a piece of c-channel vs. his fabbed piece of angle iron.

Nice job, btw, Intrepid.

IntrepidXJ · 12-28-2005, 01:48 PM

Quote:

Originally Posted by myjeepsbigger

Bingo. Just imagine a piece of c-channel vs. his fabbed piece of angle iron.

Nice job, btw, Intrepid.

thanks......c-channel sounds like a good use for that crossmember.....didn;t even cross my mind to use it.....but it's OK, all the welding practice is good for me

HULK · 12-28-2005, 06:16 PM

I understand now, but what good is that C channel (or fabbed C) doing? I dont see the bottom lip attached anywhere? Is it just to give it a rigid edge? That makes sense. All I have is big sheets of 1'4? so I guess I will be fabbing mine as well...
j

deke · 12-28-2005, 06:17 PM

I think they meant to adapt it to your needs.

HULK · 01-06-2006, 05:12 PM

I got some work done on the rear bumper this weekend. Should be done before the end of the weekend. Whats good about building these thigns is it is giving me some great seat time behind my welder. I think Im slowly getting better.

Here's the mounting bracket. I cut off the box section, and then rewelded the corners back together. The bracket includes all 8 of the stock bumper bolts, also wraps around the corner to include the rear leaf spring bolt, and wraps under to include all the bottom tow hitch bolts as well. There are also two bolts right in the middle now since it was warping out a little.

Heres where the bumper itself is at now. The D ring tabs go all the way through, and they are also welded to the tabs that will mount to the bracket on the jeep itself. It will also have wrap arounds on the ends to protect the upper quarters. That will be done tomorrow.

I'll throw up pics of it all done soon.

scrambled · 01-06-2006, 05:18 PM

Lookin good Josh. Where did you get those D-ring tabs?????

IntrepidXJ · 01-06-2006, 05:19 PM

i like it

HULK · 01-06-2006, 05:31 PM

Thanks dudes.
I got the tabs from a place called rokmen
I dont recall the website, but I am sure you could find it.

Tony · 01-07-2006, 12:32 AM

Looks good Josh, maybe you should change your sig. haha...or is this a different Jeep than before? Not bad for a guy who went to Bethel.

HULK · 01-07-2006, 09:03 AM

Tony, do I know you from Bethel? How did you know that?
And my jeep will be green again. It will all be this color when its all said and done.

Tony · 01-07-2006, 12:40 PM

Nope, from MN-Jeep. Talked with you a few years ago when I was gettin into Jeepin. I went to NWC...Moved to FL for a few years, now I am back. Hopefully I'll be able to get out on some runs this year. Jeep is in the shop right now though.

Peter T. · 01-07-2006, 04:34 PM

That rig looks sweet! Got any more pics?

HULK · 01-08-2006, 08:23 PM

Getting closer to done...

Timmay · 01-08-2006, 08:39 PM

Looks fuggin AWESOME. That's exactly the shape I want to do for my rear bumper, just the angles will start at the shackle tabs. Nice work so far. Oh, and BTW, that rear cargo area is one of the cleanest i've seen. Nice work.

MiguelXJ · 01-09-2006, 02:49 AM

Can anyone make me a drawing explaining HOW to make this type of corner??

thanks

MiguelXJ · 01-12-2006, 02:26 AM

Quote:

Originally Posted by MiguelXJ

Can anyone make me a drawing explaining HOW to make this type of corner??

thanks

BTT ??

HULK · 01-12-2006, 08:11 AM

Miguel, take a piece of box, cut a notch in the back to get the first bend. Then cut the angle you want out of the new short section you have. Box it back in with strap steel. I just made mine complicated with lots of edges.

Update: Finally done. I added gussets to the vertical mounts to stiffen it up. Also added a piece to the back so there isnt a gap between the rig and the bumper.
Now I just gotta tighten everything I have done and recheck that everything is right that I have changed so it is driveable, and then it is off to Paul's to get it's cage. Should be gone by next weekend. Yeehaw...

Mark Hinkley · 01-12-2006, 08:20 AM

Make sure to tie in your bed sides to the cage when you get to that point.

You seem to have reinforced that area some but that is the worst part to cut off your jeep without MAJOR reinforcing!

hinkley

HULK · 01-12-2006, 08:53 AM

They will get tied in once the cage is in. Now worries. Thanks for the reminder though!
j

HULK · 02-22-2006, 09:21 AM

Progress on my heep is slow coming now that it is off getting its cage...
Half doors are almost done. Leaving to get canvas covers this weekend. And yes, I did try to paint them a little in the cold before I aksed the quesiton, so that is why they look like butt....

Also making progress on the rear axle. It leaves to get narrowed tomorrow night.

Can you say 35 spline? aww yeah.....

XJAndy · 02-22-2006, 09:31 AM

I hate all you people with money to build jeeps and a place to do it.

Nice job by the way.

willy_fricken_wonka · 02-22-2006, 01:41 PM

that looks very nice, cant wait to see the finished jeep

krys yj · 02-22-2006, 02:04 PM

Quote:

Originally Posted by XJAndy

I hate all you people with money to build jeeps and a place to do it.

Nice job by the way.

x2, thats some great work...keep us updated with lots of pics

12-28-2005, 08:36 AM	#1
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	XJ rear box portion- necessary? I am doing a fair amount of cutting on my heep, and am about to start on my rear bumper. I obviously want it to be as high clearance as possible. I would like to angle up the ends as much as possible, but these boxes are in the way. How necessary are they? I dont know what it does or what it is for. Can I trim it? Should I box it in with 1/4" once I am done trimming it? Or is it fine to just hack it off and leave it? THanks for the structural help.... __________________ My jeep is green

12-28-2005, 08:38 AM	#2
deke im a sicko Join Date: Dec 2003 Posts: 7,309	I'm working on trimming the same pieces right now. They are part of the tie in for the box around the upper shackle bolt like I'm sure you are well aware of. So we'll need to re-enforce the area to make up for the lack of box support __________________ SEARCH<br /><a href="http://www.google.com" target="_blank">www.google.com</a> or <a href="http://www.pirate4x4.com" target="_blank">www.pirate4x4.com</a><br />or use jeepin's own easy to use one at the top of the page<br /><br />jaydee is my hero

12-28-2005, 08:56 AM	#4
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	Yes, cage is next. So, what would you recommend doing to reinforce that area? __________________ My jeep is green

12-28-2005, 08:58 AM	#5
deke im a sicko Join Date: Dec 2003 Posts: 7,309	Depends on how much you are cutting. Look at the direction of the force with the body pushing down onto the spring. Find where you can distribute that load out to... and re-enforce. I wouldnt use anything over 3/16. __________________ SEARCH<br /><a href="http://www.google.com" target="_blank">www.google.com</a> or <a href="http://www.pirate4x4.com" target="_blank">www.pirate4x4.com</a><br />or use jeepin's own easy to use one at the top of the page<br /><br />jaydee is my hero

12-28-2005, 09:10 AM	#6
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	I was planning on cutting it like this. SO, should I just plate that angle back in? __________________ My jeep is green

12-28-2005, 09:12 AM	#7
deke im a sicko Join Date: Dec 2003 Posts: 7,309	Theres going to be 2-3 layers of steel there that are now just sitting next to each other. I'd weld that cut edge up the entire length. then put a piece of 3/16 on the backside and have some holes for plug welds __________________ SEARCH<br /><a href="http://www.google.com" target="_blank">www.google.com</a> or <a href="http://www.pirate4x4.com" target="_blank">www.pirate4x4.com</a><br />or use jeepin's own easy to use one at the top of the page<br /><br />jaydee is my hero

12-28-2005, 10:06 AM	#11
IntrepidXJ Trail Guide Join Date: Jul 2003 Location: Grand Junction, CO Posts: 3,033	i did something similar to myjeepsbigger using a piece of 4" flat with a 1" piece of flat welded 90 degrees at the bottom for rigidity. This really helps stiffen up the rear crossmember. can see it in this pic I have not built a new rear bumper yet, but will tie them together when I do. I had also considered cutting like you are thinking, but have not made up my mind yet....will continue watching this thread __________________ Randy Langstraat .: myXJ.net \| adventureJK.com :.

12-28-2005, 12:35 PM	#12
98XJDMB Trail Guide Join Date: Mar 2004 Location: cleveland, Ohio Posts: 4,027	i can't help you, but damn thats a nice chop job __________________ -Dave '08 JKU Sahara, Dark Green, Bone Stock Old and Gone: 98 XJ Red, 3" OME lift, 31" All-Terrains, RE H&T SYE, H.A.D. Driveshaft, JKS Discos, JKS trackbar

12-28-2005, 06:16 PM	#15
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	I understand now, but what good is that C channel (or fabbed C) doing? I dont see the bottom lip attached anywhere? Is it just to give it a rigid edge? That makes sense. All I have is big sheets of 1'4? so I guess I will be fabbing mine as well... j __________________ My jeep is green

12-28-2005, 06:17 PM	#16
deke im a sicko Join Date: Dec 2003 Posts: 7,309	I think they meant to adapt it to your needs. __________________ SEARCH<br /><a href="http://www.google.com" target="_blank">www.google.com</a> or <a href="http://www.pirate4x4.com" target="_blank">www.pirate4x4.com</a><br />or use jeepin's own easy to use one at the top of the page<br /><br />jaydee is my hero

01-06-2006, 05:12 PM	#17
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	I got some work done on the rear bumper this weekend. Should be done before the end of the weekend. Whats good about building these thigns is it is giving me some great seat time behind my welder. I think Im slowly getting better. Here's the mounting bracket. I cut off the box section, and then rewelded the corners back together. The bracket includes all 8 of the stock bumper bolts, also wraps around the corner to include the rear leaf spring bolt, and wraps under to include all the bottom tow hitch bolts as well. There are also two bolts right in the middle now since it was warping out a little. Heres where the bumper itself is at now. The D ring tabs go all the way through, and they are also welded to the tabs that will mount to the bracket on the jeep itself. It will also have wrap arounds on the ends to protect the upper quarters. That will be done tomorrow. I'll throw up pics of it all done soon. __________________ My jeep is green

01-06-2006, 05:18 PM	#18
scrambled Trail Guide Join Date: Jun 2005 Location: MN Posts: 244	Lookin good Josh. Where did you get those D-ring tabs????? __________________ Yes, I just said that!

01-06-2006, 05:19 PM	#19
IntrepidXJ Trail Guide Join Date: Jul 2003 Location: Grand Junction, CO Posts: 3,033	i like it __________________ Randy Langstraat .: myXJ.net \| adventureJK.com :.

01-06-2006, 05:31 PM	#20
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	Thanks dudes. I got the tabs from a place called rokmen I dont recall the website, but I am sure you could find it. __________________ My jeep is green

01-07-2006, 12:32 AM	#21
Tony Trail Guide Join Date: Oct 2002 Location: Minnesota, yeah sure you betcha Posts: 510	Looks good Josh, maybe you should change your sig. haha...or is this a different Jeep than before? Not bad for a guy who went to Bethel. __________________ My Blog...Check it!

01-07-2006, 09:03 AM	#22
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	Tony, do I know you from Bethel? How did you know that? And my jeep will be green again. It will all be this color when its all said and done. __________________ My jeep is green

01-07-2006, 12:40 PM	#23
Tony Trail Guide Join Date: Oct 2002 Location: Minnesota, yeah sure you betcha Posts: 510	Nope, from MN-Jeep. Talked with you a few years ago when I was gettin into Jeepin. I went to NWC...Moved to FL for a few years, now I am back. Hopefully I'll be able to get out on some runs this year. Jeep is in the shop right now though. __________________ My Blog...Check it!

01-07-2006, 04:34 PM	#24
Peter T. Trail Guide Join Date: Sep 2002 Location: Sunnyvale, CA Posts: 131	That rig looks sweet! Got any more pics? __________________ 00'XJ, 4.5"Rubicon,32" BFG Muds,and other do dads. We're here for a good time not a long time!

01-08-2006, 08:23 PM	#25
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	Getting closer to done... __________________ My jeep is green

01-08-2006, 08:39 PM	#26
Timmay Join Date: May 2004 Location: NJ/PA Posts: 19,076	Looks fuggin AWESOME. That's exactly the shape I want to do for my rear bumper, just the angles will start at the shackle tabs. Nice work so far. Oh, and BTW, that rear cargo area is one of the cleanest i've seen. Nice work. __________________ Tim Diekmann Liquid Iron Industries tim@liquidironindustries.com http://www.LiquidIronIndustries.com (856)-336-2639 '13 LII Eliminator Chassis - "Fred" Ultra 4 #4343 '03 3/4 ton Cummity Cummins - "The Black Knight" '03 KTM 450 - "Katoom" '99 Kenworth T2000 - "Shamu"

01-09-2006, 02:49 AM	#27
MiguelXJ Miggy rules! Join Date: Aug 2002 Location: Portugal Posts: 7,279	Can anyone make me a drawing explaining HOW to make this type of corner?? thanks __________________ Originally posted by Vetteboy: - "For some people, it's about getting over the biggest obstacle ever. For others, it's about maximizing your vehicle's capabilities as it sits, and always pushing its limits just a little further." 88XJ \| 2.1TD \| 3" \| 31s (Sold)

01-12-2006, 08:11 AM	#29
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	Miguel, take a piece of box, cut a notch in the back to get the first bend. Then cut the angle you want out of the new short section you have. Box it back in with strap steel. I just made mine complicated with lots of edges. Update: Finally done. I added gussets to the vertical mounts to stiffen it up. Also added a piece to the back so there isnt a gap between the rig and the bumper. Now I just gotta tighten everything I have done and recheck that everything is right that I have changed so it is driveable, and then it is off to Paul's to get it's cage. Should be gone by next weekend. Yeehaw... __________________ My jeep is green

01-12-2006, 08:20 AM	#30
Mark Hinkley XJ guru Join Date: Jul 2004 Posts: 72	Make sure to tie in your bed sides to the cage when you get to that point. You seem to have reinforced that area some but that is the worst part to cut off your jeep without MAJOR reinforcing! hinkley

01-12-2006, 08:53 AM	#31
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	They will get tied in once the cage is in. Now worries. Thanks for the reminder though! j __________________ My jeep is green

02-22-2006, 09:21 AM	#32
HULK Trail Guide Join Date: Aug 2003 Location: Minnesota Posts: 722	Progress on my heep is slow coming now that it is off getting its cage... Half doors are almost done. Leaving to get canvas covers this weekend. And yes, I did try to paint them a little in the cold before I aksed the quesiton, so that is why they look like butt.... Also making progress on the rear axle. It leaves to get narrowed tomorrow night. Can you say 35 spline? aww yeah..... __________________ My jeep is green

02-22-2006, 09:31 AM	#33
XJAndy label nerd Join Date: Sep 2002 Location: Asheville, NC Posts: 10,295	I hate all you people with money to build jeeps and a place to do it. Nice job by the way. __________________ They say you are smart if you have your PHD, I say the real smart man is the one who figures out how to get paid to fish.

02-22-2006, 01:41 PM	#34
willy_fricken_wonka Trail Guide Join Date: Jan 2004 Location: michigan is home, ohio for school "UNO" Posts: 368	that looks very nice, cant wait to see the finished jeep __________________ 94 506 C.I.D YJ on 40's....$5500 74 304 C.I.D E.F.I CJ-5 on 33's....$7500 Getting Pulled Out By Your Little Brothers Stock 4.0L.....PriceLess 1994 XJ. H.O (BMF) In the process of being Cut, Locked, and Ready for trails 2000 dodge neon (can't beat 40mpg)