I had an idea, but as I have no experience with custom metal work am not sure what the feasibility is.

Instead of doing a steel bumper, I would like to do either a lighter weight steel or an Aluminum bumper that is made of a center piece, and two bumper end caps that attach to the steel bumper already on the vehicle.

I don't want to lift and put on stiffer springs, because it's mostly a city car and I have to get in and out of garages, also I spend a lot of time on the highway and would have to to actually go four wheeling anyway. So I prefer stock springs and height.

Is this something I could measure and take a crack at myself? Any guesses as to what a specialist welder would charge for a project like this?

 

Cost will be high, as aluminum isn't cheap, and neither is the skill to fab and tig weld it.
It will also bend much easier in a crash.

 

I'm really just interested in something that can be fixed if dented unlike the stock plastic POS.

I got inspired by my neighbors Rubicon. It has a modular bumper, and I thought. Gee, that is a good idea.

I am sure I could make one myself, but it would probably end up looking like a junior high project.

 

I had the Rough Country modular bumper on one of my 05 Jeep Wranglers. I liked it a lot minus the crappy bolts it came with (I replaced them all with high quality grade 8 stuff)

 

In hindsight, I'd love to shed some steel in favor of aluminum. If you can figure it out, and afford it, you'll thank yourself later.

 

 

That is what I am thinking. I am going to have to read up about it. Don't mind if it is a thin sheet metal, and although I would prefer aluminum due to corrosion resistance if cost were better, easier to work with I would use it.

I will have to research how to come up with a template, but I have no idea how to use drafting software.

 

If you can't use autocad or solidworks(I can't either, fortunately my Dad can), all you need for a bumper is a tape measure and protractor.

 

I'M in dire need of a front bumper and will prob just go with the da5645 steel winch bumper....