Foreword.

After my weekend trip to countryside, I got my fornt bumper and grill significantly damaged. Dowhilling the ice covered road did it's job    There is no advantage to restore broken or buy new stock parts, so I decided to desing and build up a proper bumper.

Thing is I got Calmini's shackle reverse, therefore I'm interesting in designing of bumper's attachment to the frame without touching those shackle reverse parts.
Maybe someone here has already built his/her own front bumper in listed above setup? Any CAD drawings or just drawings with dimensions would very appreciable.

Thanks!!!

P.S.: I was searching, but find nothing.

Had the same problem when I found a good deal on my ARB Bumper, I have/had the 5" combo. I simply went back to shackles up front, lost about an inch of lift but the bumper bolted right up.

I took a quick look at Calmini's Shackle reverse kit and , from what I saw, you will need to mount your bumper to the same end-frame holes that the shackle reverse system is mounted to.



This probably will require longer bolts (grade 8 or better!).  I see that there appears to be frame spacers included with the kit (just above the box-steel pieces) to keep the mounting bolts from crushing the frame from overtightening, so that is a good thing.  Most quality bumper mounting kits include those spacers so that the bumper is securely mounted to the frame without crushing or ripping it during impact.

Since you do have the S/R kit, you probably won't be able to install most manufactured aftermarket bumpers (in case you were thinking of it) because the S/R system has changed the mounting distance between the frames.  Building your own bumper - which would compensate for this mounting distance change is a good option!

Practically speaking there is no other mounting points except for the four bolt holes that the Calmini S/R system has used.  Welding something to the frame for a bumper mount is a distant second choice in my opinion.  I bet that Calmini offers a bumper that works with their S/R kit thus proving that the mounting holes will take the attachment of both a S/R kit AND an aftermarket bumper...  Call them and find out.

Thanks for answer ack!
Those are not frame spacers, those are for poly bushings bolts. I've made spacers by myself when I was installing Calmini 3.5 Combo System.

Yes, Calmini actually offers proper bumper for an S/R kit, but problem is I live a bit far from US, so mailing a bumper is quite expensive for me (it's about one and half of bumper's price itself, ~$900 in total).

I'm afraid of designing bumper on my own, because if it won't fit I would loose about $250-$300 for stell and work. That's why I'm looking for "successful"l drawings or CADs.

I'm afraid of designing bumper on my own, because if it won't fit I would loose about $250-$300 for stell and work. That's why I'm looking for "successful"l drawings or CADs.

I've got a Tracker, but same idea.  We created a bumper out of cardboard first, so we could be sure of the looks and fit.  This is the thread of my progressing build.  (Bumpers on first page.)
http://www.zukiworld.com/forum/index.php?topic=22395.0

Drone637 started with the mounts and an idea, then just built to fit both front and back.  2x2 square tube, and it doesn't bend.

That reminds me, I really should put some reverse lights on it while we have it in the shop...

Dimitros-

My second welding project was a bumper for my Samurai. There were no drawings, just some careful thought.

The hardest part was buying and cutting and drilling two 1/4 inch thick 4x4x 4inch long angle iron pieces using the hold-down eye as a template.  I used a felt tip pen to mark what needed to be cut off or drilled, vicegripped the two pieces together, and started grinding out the circular area - checking for proper fit - until I had enough material removed so that the bolt holes would have enough metal around them to hold.  I also made sure that the face of the angle irons would be perpendicular to level ground so the bumper would not be "canted" top or bottom forward.  Once the two angle irons were cut and drilled, I separated them and bolted them to the inside of the frame.  This created two flat surface that I could weld my bumper to.

In my case I used a piece of 11 gage 2x4 inch box beam.  You can use anything that you want although something flat works best with this angle iron mount.  Add a winch plate, a receiver tube, brackets for a towbar, lighting holes, whatever.  I turned my bumper into an air tank.  Unfortunately, my welding skills at the time were not good enough to make a very air-tight tank so it never got used... HOWEVER - the bumper worked great! It didn't show any attachment weld failures for the 8 years that I ran with it.

I hope that this helps!

Thank you  ack, useful info man. Just a little unusual for me to convert inchs to mm
 
Decided. I think I'll try to design it myself, but as for cutting&welding it, it's better be someone with good welding experience.

Anyway, drawings are appreciable.

Thank you  ack, useful info man. Just a little unusual for me to convert inchs to mm

Someday, us Americanos will learn the the language of Metrics.

We are getting there!