Advice sought, post body lift rear bumper reinforcement.

[MrSmithsTB]

I am ready to go off roading again. Due to the body lift I had before, the front and rear impact bars were cut for relocation. I took care of the front one on a whim today by cutting and drilling a piece of 3/16 angle steel so I can remounted the tow hooks. The rear is a different story. For the 2" body lift, it was cut down to have only one factory bolt holding it on each side. I am concerned that these two bolts will not provide enough structural integrity to withstand the force of an extraction if I get stuck or need to pull someone else. I would also like to know that I can safely tow if needed. My thought is to drill as second hole, as well as add a steel plate that will use a third hole, to spread out the load and regain the integrity and peace of mind. Other than that, I would be left with replacing the impact bar. What, if anything, does anyone think I should do in order to assure I do not rip the bumper off.

[mikepeters1983]

Dont use blind bolts, they dont stay tight and break easy. If you got the 4 from Zone then I think that you should be good, one more idea is just to weld your bumper to it and go from there.

[MrSmithsTB]

I would be using at least grade 8 bolts, with locking nuts and thread locker. I sold the body lift back in January. I also still have the extra original bumper bolts which I could find nuts to fit. Want to stay away from welding it in case it needs to come off for any reason.

[mikepeters1983]

Thats the same reason why I aint welded mine yet, but I might have to no matter what. Just for a good solid mount.

[MrSmithsTB]

I realistically see no reason to weld. As long as the stress is distributed evenly and the bolts are strong enough, I would think I should be fine. Frame is thick and with a 3/16 plate added to the outside I don't think the holes will fatigue. But I've never really done anything like this before.

[mikepeters1983]

That is what I was thinking, but I might be doing it just for strength purpose.

[MrSmithsTB]

Any other opinions? I am wary about adding bolts, simply because so much material was removed. Welding....what if it has to come off? Pita. Replacing it? There aren't any reasonably priced ones in the area and shipping would be a bear.

[Trail X]

For those of us that don't have a body lift...



I can't help without knowing what you're looking at.

[MrSmithsTB]

Here is the best I can come up with without taking my bumper off while I'm at work. Install PDF from Zone, the picture of the cut line is on page 15(fig 28), cut itself is on page 17(fig 32).
http://zoneoffroad.com/Instructions/C9212.pdf

[Gordinho80]

Bot, is there room on the other side of the bumper mount(opposite side of this image), to drill a hole around where I marked with red? If so, you can get a good piece of angle(blue outline), drill out 3 holes...

[MrSmithsTB]

That is exactly what I was thinking. I will need new hardware and I will have to grind the nut off of the factory hole, but the space is there to do that. Also Think I would want to put a flat plate on the outside of the frame rail for more rigidity. I already have leftover 90deg steel from the tow hook reinforcement I did last weekend.

[Trail X]

That cut is really in a bad spot. If you're planning to tow and recover using your rear hitch... I'd say your only bet is to get a junkyard part. Otherwise the liability is in your hands.

[MrSmithsTB]

There must be something that will strengthen it without going too far concerning effort and investment. If the reloc. brackets are sufficient with that cut, I don't know why some extra material and mounting points wouldn't cure the weakness. The only concern I have from a standpoint of strength is the integrity of the frame and bolts. All of that force pulling on 2 mounting points? Could stretch the holes or shear the bolts. Adding 4 more(2 per side) would distribute that force more evenly, making the assembly much stronger. Though, I could always weld some length back onto the bumper. Even the cost of an el cheapo stick welder is less than the cost of any junkyard bumpers that are close enough.

[fishsticks]

There must be something that will strengthen it without going too far concerning effort and investment. If the reloc. brackets are sufficient with that cut, I don't know why some extra material and mounting points wouldn't cure the weakness. The only concern I have from a standpoint of strength is the integrity of the frame and bolts. All of that force pulling on 2 mounting points? Could stretch the holes or shear the bolts. Adding 4 more(2 per side) would distribute that force more evenly, making the assembly much stronger. Though, I could always weld some length back onto the bumper. Even the cost of an el cheapo stick welder is less than the cost of any junkyard bumpers that are close enough.

I'm going to guess you didn't keep your factory bumper pieces?

I kept mine to weld back on just in case...

[MrSmithsTB]

I thought I did, but they must've gone in the trash with some other scrap I cleaned out a couple months ago. Since I am going to body lift again, and will be welding my own brackets, I pretty much need something that will create a safe recovery point until I do the lift and brackets.

[fishsticks]

I thought I did, but they must've gone in the trash with some other scrap I cleaned out a couple months ago. Since I am going to body lift again, and will be welding my own brackets, I pretty much need something that will create a safe recovery point until I do the lift and brackets.

I'll poke around my garage and see if I can locate mine. Yours for shipping cost if you want them. I'm committed to being body lifted forever after some of the mods I've made.

[MrSmithsTB]

Sure. If you find em I will gladly use them.