How to Build a Custom Bumper for Jeep Cherokee
- 1). Trace the exact shape of your bumper onto graph paper. Outline the shape from the front, top, bottom and from a 45-degree angle. Each time, use the same scale ratio, using the squares of the graph paper as your units of measure. Scale each one to represent 1 inch. You should be able to fit the whole bumper design on one sheet. Draw all the curves and holes using simple lines.
- 2). Follow the scale drawings to transfer the shape onto a solid block of wood. Use a dark carpenter's pencil to trace the outline and mark off areas where you will need to carve.
- 3). Carve out the shape into the block of wood. Remember to allow for the curve of the bumper, which cannot be represented by a two-dimensional drawing. Use sharp wood chisels and a power drill with a grinding bit to finish your carving.
- 4). Apply a thick coat of mold release to your bumper form. Be sure to get it in all the corners, divets and around the rims of the holes.
- 5). Mix up a large batch of fiberglass resin. Then layer strips of fiberglass along the form, painting them with resin as you go. Cover the entire form with fiberglass strips and resin. Then let the resin dry for 24 hours, or as directed in the instructions.
- 6). Tap the form when dry with a rubber mallet until you hear it popping from the form. Gently pry up the edges of the form until you can release it from the mold.
- 7). Sand your new Jeep bumper with 120-grit then 360-grit sandpaper until smooth. Drill the mounting holes in the bumper. Cut out any other accessory slots and holes you want for fog lights, hitches or anything else. Once complete, mount the bumper on your Jeep.
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