Assembly Instructions For

1999-2004 WJ Jeep Front Bumper Winch Kit

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Assembly Instructions For

1999-2004 WJ Jeep Front Bumper Winch Kit

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Thank you for your purchase at DIY Offroad!For more great products checkout our website, www.diyoffroadproducts.com or call us at 503-931-7069. If you have any questions or concerns please don’t hesitate to contact us.

• ½” Metal Drill Bit• Hand Drill• MIG Welder w/ Solid Wire• Grinder• 4 1/2’’ Flapper Disk• 7’’ Sander for Finish

Mounting Bracket Assembly• (5) Slotted Mounting Brackets• (4) Bolt-on Tab Mounting Bracket• (6) Reinforcement Plates• (3) Triangle Mounting Brackets

Center Section Assembly• (1) Center Section - Pre Bent @90°• (8) Skid Plate - Weld On• (7) Skid Plate Gussets - Weld In 6x• (9) Triangle Top Filter Plate• (10) Shackle Tabs

Wing Section Assembly• (2) End-cap Wing Section Plates• (2) Top Wing Section Plates• (2) L/R Wing Sections - Pre Bent

99-04 WJ BUMPER KIT

“Do It Yourself ” Front bumper kit for your WJ Jeep. Welding and grinding required, fabri-cate your own off road front bumper and save! All bumpers are made from 3/16’’ thick hot rolled steel. Parts are pre-formed and ready for your welding and grinding skills.Includes mounting brackets.• 10x 1/2-13 x 1.500’’

• Grade 5• 10x 1/2’’ Lock Washers• 6x Flat Washers

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HARDWARE INCLUDED

ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 99-04 WJ FRONT BUMPER KIT

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Remove the plastic bumper skin from the vehicle.

Inside the bumper receiver slots is a reinforcement bracket. Remove the small plate.

The bumper re-ceiver slots have a sheet metal lip. Cut away this lip on the bottom and sides to open up the full tube.

Grind the edges smooth on the lip. Then expand the two holes to ½”.

Tools - Use cutoff wheel or body saw to grind off bottom lip

Use 1/2’’ Drill here

ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 99-04 WJ FRONT BUMPER KIT

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Weld the mounting brackets to form mounting bracket assemblies. The tabbed mounting bracket includes a slot for the washer on the slotted mounting bracket. Weld Tab, Slot and washers.(4,5)

Use the mounting bracket assemblies to fasten the bumper to the vehicle LOOSLEY.(4,5,6)

(DO NOT tighten yet)

The front lip bends to 90 degrees while the wings fold to meet the front lip (around 67 degrees).

Weld the side end-cap plate and top wing plate to the wing assemblies.(2)

Fully weld and grind pre-bend center section.(1)

ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 99-04 WJ FRONT BUMPER KIT

STEP

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Mate the wing sections align with the center section wings.(1,2)

Tack weld triangle mounting brackets to inside wing sec-tions with 29.5 inch spacing.(1,2,3)

Bolt the bumper to the vehicle without the skid plate to allow for easy access underneath. Once the skid plate is fixed, access under-neath is limited.

Weld Triangle mounting brackets inside the wing sections and on the center section only.(1,2,3)

(The best way is to lay the part upside-down on a flat metal table.)

TEST FIT

Don’t Weld Here (where the skid plate sits)

ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 99-04 WJ FRONT BUMPER KIT

STEP

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Tack Weld skid plate and then gussets underneath between the skid plate and center section.(1,2,7,8)

Weld Triangle Top Filler Plates at 90 degrees to the center section front lip. (1,9)

Once all tacked up, you may begin welding 6-8 inches at a time.

Insert shackle tabs into the slots in the center section and weld to center section.(1,10)