Assembly Instructions

For

1999-2004 WJ Jeep
Front Bumper Non-Winch Kit

Thank you for your purchase at DIY Off Road Products!

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.


Assembly Instructions
For
1999-2004 WJ Jeep
Front Bumper Non-Winch Kit
Mounting Bracket Assembly (L/R)
• (3) Triangle Mounting Bracket
• (5) Tab Mounting Brackets
• (6) Slotted Mounting Brackets
• (7) Reinforcement Plates

Center Section Assembly

• (1) Center Section
PARTS LIST

• (2) Skid Plate Gussets

• (4) Shackle Tabs

Wing Section Assembly (L/R)

• (8) L/R Wing Sections
• (9) Bottom Filler Plate
• (10) Top Filler Plate
• (11) Outer End-cap Filler Plate
• (12) Inner End-cap Filler Plate 99-04 WJ BUMPER KIT

• ½” Metal Drill Bit

• Hand Drill Weld your own DIY 99-04 Grand Cherokee
• MIG Welder w/ Solid Wire WJ Front NON-Winch Bumper Kit
TOOLS NEEDED

• Grinder This precision cut and formed kit is perfect for

• 4 ½” Flapper Disk
• 7” Sander for Finish
HARDWARE INCLUDED
• 10x ½-13 x 1.500”
• Grade 5
• 10x ½” Lock Washers
• 6x Flat Washers
the “Do It Yourself ” off road enthusiast who
wants to fabricate their own off road winch
bumper for the WJ Jeep Grand Cherokee
This heavy duty steel bumper is made from all
10 gauge” (.135’’) thick hot rolled steel
Weight: 67 lbs.

Thank you for your purchase at DIY Off Road Products!

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

STEP
Remove the plastic bumper
1 skin from the vehicle.

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

The bumper
receiver slots
STEP have a sheet
metal lip. Cut
3 away this lip on
the bottom and
sides to open up
the full tube. Tools - Use cutoff wheel or body saw to grind off bottom lip

Grind the edges smooth

STEP on the lip. Then expand the
4 two holes to ½” that the
slotted mounting
bracket will line up to.

Use 1/2’’ Drill here

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

Form mounting bracket

assemblies. Weld nuts to
STEP top of the Slotted
Mounting Brackets (6)
5 above each bolt hole. The
Tab Mounting Bracket (8)
is welded in the slot of the
Slotted Mounting Brackets
(6).

STEP
Use the mounting bracket assemblies
6 to fasten the bumper to the vehicle
LOOSELY (Do not tighten yet).

STEP
Bolt Triangle Mounting Bracket (3)
7 to body bracket assemblies.

STEP Tack weld Triangle Mounting

Bracket (3) to inside Center
8 Section (1).
ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 99-04 WJ FRONT BUMPER KIT

STEP

9 Remove bumper from vehicle and finish welding.

Fully weld and grind the pre-bent center section with Triangle
Mounting Brackets (3) and Skid Plate Gussets (2).
STEP

10

STEP
Insert Shackle Tabs (4)
11 into the slots in the Center
Section (1) and weld.

Form Wing Assemblies by welding the filler plates to the L/R Wing
Sections (13).
STEP

12

Do not weld the inner end-cap filler plate (12) yet.

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

STEP Mate the Wing Assemblies

with the Center Section (1).
13 The best way is to lay the
part on a flat metal table.

STEP
Step 14 - Tack weld inner
14 end-cap filler plate (12).

STEP

15 Bolt the bumper to the vehicle.

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