So, I got the bumper (front) all powder coated and the factory bumper came off like a charm — then the trouble started. I took the crush cans off, but the new bumper would not slide over the frame horns at the front. Like, barely wouldn't go on, maybe a 1/16". I called Goliath and the guy was very nice. He said that on some DIIs there are plates welded to the sides of the frame horns. This def. matches with what I'm seeing. They look like they're riveted? It certainly looks like if I could get them off, that would provide the necessary clearance for the bumper to slide on. Just don't know the best way to remove those plates. Any thoughts welcome...

(And don't get me started on moving the washer bottle...)

BTG

 

I have a Goliath front bumper but it was on it when I purchased.... I can look at it tomorrow if you want me to scope it out?

 

I appreciate it, but I wonder if you'll be able to see anything. What I'm talking about is what the bumper's brackets slide over. Did you have any trouble sliding yours on?

 

You should be able to spread open the bracket on the bumper slightly with a pry bar and a block of wood.

 

That's a good idea. I'll try that!

 

What was your solution? I tried mounting a Goliath today and had a similar issue.

 

That's exactly what I did with the Goliath bumper on my '04. It took a little figuring out, but I was able to get it bolted up by myself with a floor jack, a couple of jack stands, and some scrap pieces of wood to use for some extra height adjusters/balancing points on the jack stands. It's definitely a 2-3 beer job. Not a 1 beer job.

Pic is right after install and a wet and rainy test drive after mounting. I was able to pick up the bumper from Goliath in person while I was driving back to the PNW from FL last spring. Great guys.

 

Nice! I texted the guy at Goliath and he told me to grind off the thin plates on the inside of the frame rails. Seems like this might slightly decrease the shear strength of the rails, but I'm not planning on doing anything where that will be an issue. Bumper fit great after i did that, I'd say 2 beer job (based on actual data...).