Rubicon Steel Front Bumper Inner Covers

BHo

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I noticed my fog lamp wiring was exposed when I removed my front bumper steel end caps. A little brainstorming, $10 worth of Black ABS Plastic, and a few hours total I had a clean looking solution to the problem.

Parts:
5 Pack 12x12x.062 ABS Plastic Sheets, Moldable Plastic Sheets.

=====
Problematic Exposed Electrical
33149276-822B-44C4-AD52-7A53D58F66A4.jpeg

=======
Solution:
Fabricated a cardboard template.
NOTE: you only need one side since you can flip the template for the opposing side.
C9A665D8-85E7-41F6-A54D-E1DC7554F5F3.jpeg

====
Once the cardboard template was satisfactory I cut the ABS sheets for both sides and molded the plastic contours.
A261D3BF-43D3-479D-88F2-AD3168C18079.jpeg
6E1A5696-53CA-4FC2-979A-41440B4DCE4D.jpeg
540CA886-F2EA-497C-BAC0-089C9FFF1BA7.jpeg
CA93168E-3DA5-4E45-8F93-7554C4929E0A.jpeg

====
Mounting:
I used the TWO factory Torx bolts on each side to affix the ABS plastic.
834EAFED-BD90-4963-9FEB-5FA0FF91DEBB.jpeg


I proceeded to the final step; heat/molding of bumper contours.
EF29BDA1-F331-49A1-BE1F-0CE55C622255.jpeg

13626898-EED4-4753-A727-BD20A86899F7.jpeg

====
Remove the TWO factory Torx bolts for accessing the lights if needed for future maintenance.

5085DECE-7E1C-4B99-9E0E-859FAFBD32F7.jpeg





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hoag4147

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I noticed my fog lamp wiring was exposed when I removed my front bumper steel end caps. A little brainstorming, $10 worth of Black ABS Plastic, and a few hours total I had a clean looking solution to the problem.

Parts:
5 Pack 12x12x.062 ABS Plastic Sheets, Moldable Plastic Sheets.

=====
Problematic Exposed Electrical
33149276-822B-44C4-AD52-7A53D58F66A4.jpeg

=======
Solution:
Fabricated a cardboard template.
NOTE: you only need one side since you can flip the template for the opposing side.
C9A665D8-85E7-41F6-A54D-E1DC7554F5F3.jpeg

====
Once the cardboard template was satisfactory I cut the ABS sheets for both sides and molded the plastic contours.
A261D3BF-43D3-479D-88F2-AD3168C18079.jpeg
6E1A5696-53CA-4FC2-979A-41440B4DCE4D.jpeg
540CA886-F2EA-497C-BAC0-089C9FFF1BA7.jpeg
CA93168E-3DA5-4E45-8F93-7554C4929E0A.jpeg

====
Mounting:
I used the TWO factory Torx bolts on each side to affix the ABS plastic.
834EAFED-BD90-4963-9FEB-5FA0FF91DEBB.jpeg


I proceeded to the final step; heat/molding of bumper contours.
EF29BDA1-F331-49A1-BE1F-0CE55C622255.jpeg

13626898-EED4-4753-A727-BD20A86899F7.jpeg

====
Remove the TWO factory Torx bolts for accessing the lights if needed for future maintenance.

5085DECE-7E1C-4B99-9E0E-859FAFBD32F7.jpeg
looks great. Nice craftsmanship. Now make two more and I will send you my address for mailing and a PayPal payment :LOL:
 

NYLONZ

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Sweet!!
 
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BHo

BHo

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looks great. Nice craftsmanship. Now make two more and I will send you my address for mailing and a PayPal payment :LOL:
I could possibly do a small batch run if people are actually interested.
 

hoag4147

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I would be
 
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SDot

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I could possibly do a small batch run if people are actually interested.
I'm in please! I'm guessing we'd do the heat gun part on our end?
 
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BCool

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I could possibly do a small batch run if people are actually interested.
Definitely in, if you can ship them to 02116 for less than the $25 I'd need to spend on Amazon for 3 extra sheets. Let us know!
 
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nerubi

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Thanks for the description and pictures. Just completed mine, not as great looking as yours but first time bending plastic. Going to run them awhile, see how they do then maybe do them again with a little more care. Only $9.00 so no big deal to try again later.
 

CarbonSteel

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I could possibly do a small batch run if people are actually interested.
I would be interested in a set too. I have the full length steel bumper (my end caps are still on). I assume it would still work?
 

Slowpoke

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I have the full length steel bumper, my end caps are still on. Will these work? Price?
 

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