Warn Elite JL Full Width Front Bumper!

[Stickerhead]

Pick mine up Friday with skid and VR10000 winch

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[Taurus14]

I hate full width bumpers that aren't fender flush

I live in NJ and looking for full bumper that's fender flush. Let me know if anyone finds one for the Sahara. Thanks

 

[LeoD]

I took some time for me to install mine with the Warn Zeon 10S and the skid plated, directions were not very clear and getting the fog lights to fit was a challenge. The hardest part was getting to the 6 bolts that hold the skid plate to the bumper, if you're doing this combo, try bolting the skip plate to the bumper first. NOTE, there are two Rubicon bumpers, I had the plastic one because I knew before hand I was going to replace it, mounting instructions are slightly different from the metal bumper. Also, you do have to cut the frame rails as the instructions say, but it's pretty easy.

 

[mwilk012]

I took some time for me to install mine with the Warn Zeon 10S and the skid plated, directions were not very clear and getting the fog lights to fit was a challenge. The hardest part was getting to the 6 bolts that hold the skid plate to the bumper, if you're doing this combo, try bolting the skip plate to the bumper first. NOTE, there are two Rubicon bumpers, I had the plastic one because I knew before hand I was going to replace it, mounting instructions are slightly different from the metal bumper. Also, you do have to cut the frame rails as the instructions say, but it's pretty easy.

What’s the purpose of cutting the frame rails? My bumper finally arrived in the mail and I haven’t even unboxed it yet, I have to go buy some tools first.

 

[Texas_Yote]

What’s the purpose of cutting the frame rails? My bumper finally arrived in the mail and I haven’t even unboxed it yet, I have to go buy some tools first.

If you are going to use the Zeon winch there are two tabs that contain unused bolt holes that need to be trimmed just on the other side of the front of the bumper. The purpose is purely to fit the Zeon winch otherwise it is not needed...

If you plan to do the install yourself make sure to put the large bumper mount bolts in first prior to install the fog lights. The instructions will have you do the fog lights first, that is a TERRIBLE idea. Also, make sure to use the bolt press on fastener to keep them in place...the instructions do not mention that..

from the image above, here are the areas you need to cut to make it fit

 

[mwilk012]

Ah, well I have the VR-8S winch and hope that it fits well without any sort of trimming, I didn't feel like buying a cutting tool.

 

[Texas_Yote]

Ah, well I have the VR-8S winch and hope that it fits well without any sort of trimming, I didn't feel like buying a cutting tool.

I've test fitted a VR10s and it is fine. VR8 will fit perfectly.

 

[LeoD]

Hi Guys, Supposedly the Zeon winch is slightly larger thank some others. I tried to fit the winch without cutting the frame raise, it wouldn't fit, so I cut exactly as they described and it fit (barely), so yes, they definitely have to be cut. It was pretty easy, I used a hand held jig saw with a metal cutting blade.

After about a month now, there are areas on he bumper by the cutouts and welds that are starting to show some rust, anyone else hav that problem?

 

[Texas_Yote]

Hi Guys, Supposedly the Zeon winch is slightly larger thank some others. I tried to fit the winch without cutting the frame raise, it wouldn't fit, so I cut exactly as they described and it fit (barely), so yes, they definitely have to be cut. It was pretty easy, I used a hand held jig saw with a metal cutting blade.

After about a month now, there are areas on he bumper by the cutouts and welds that are starting to show some rust, anyone else hav that problem?

Nothing here yet; it's been raining non stop here too. Ill keep an eye on it and let ya know.

 

[achaffee86]

I took some time for me to install mine with the Warn Zeon 10S and the skid plated, directions were not very clear and getting the fog lights to fit was a challenge. The hardest part was getting to the 6 bolts that hold the skid plate to the bumper, if you're doing this combo, try bolting the skip plate to the bumper first. NOTE, there are two Rubicon bumpers, I had the plastic one because I knew before hand I was going to replace it, mounting instructions are slightly different from the metal bumper. Also, you do have to cut the frame rails as the instructions say, but it's pretty easy.

Hey I'm in the middle of installing mine and I'm having a hard time. Would you mind answering some questions for me?

 

[achaffee86]

I had a plastic bumper and am following those directions. First question is how did you route the wiring harness for the fog lights?

Second question: How did you install the frame doubler plate? It says put in bolts but never references nuts or torquing them down.

Third question: Where the hell is the frame support gussets? The step says to remove two nuts holding the frame support gussets. The picture makes no sense to me.

Fourth question: Did you trim both sides of your frame rails to fit a zeon winch?

Please help!

 

[Texas_Yote]

I had a plastic bumper and am following those directions. First question is how did you route the wiring harness for the fog lights?

Did you get the skid guard as well? If not there are holes you can use to clip the harnes into. If you did, there are slightly less of them to use but you can reuse the factory plastic plugs and pull the harness tight. For saggy area's, use a zip tie to bundle. If your plugs feel like they will not old in the bumper, you can bundle and use a zip tie to make it all snug.

Second question: How did you install the frame doubler plate? It says put in bolts but never references nuts or torquing them down.

Doubler plate? Are you saying the small plate with the square holes what goes inside the rail mounts? If so the bolts are help in place by the plate, the quare portion of the bolt sits inside the plate and holds it in place while you tighten the nut on. This is done much easier with an impact, electric or air.

Third question: Where the hell is the frame support gussets? The step says to remove two nuts holding the frame support gussets. The picture makes no sense to me.

To get the bumper on/off there are 4 bolts to remove, the new bumper will only replace 3 of them. There are some pieces (this may be one of them) where steel bumper instructions are mixed into the plastic bumper.

Fourth question: Did you trim both sides of your frame rails to fit a zeon winch?

Should just be the driver.

Please help!

I had a plastic as well, ill see if i can help. See answers above in bold. If you have picture or reference the section in the instructions that would help me add more clarity.

 

[achaffee86]

I had a plastic as well, ill see if i can help. See answers above in bold. If you have picture or reference the section in the instructions that would help me add more clarity.

This is awesome help. I wish i would've seen your response earlier because I already started trimming the passenger side but whatever. No big deal.

My last question is did your skid plate and your winch bracket both attach to the same point on the frame rails? Looking at the instructions it seems that's what its asking for.

 

[Texas_Yote]

This is awesome help. I wish i would've seen your response earlier because I already started trimming the passenger side but whatever. No big deal.

My last question is did your skid plate and your winch bracket both attach to the same point on the frame rails? Looking at the instructions it seems that's what its asking for.

Yes they do if you go the skid plate with the bumper (i had to wait due to back-order) I suggest mounting the front 5 bolts first prior to hanging the bumper. Otherwise the outer most 5 bolts are a pain in the ass with man hands...

 

[mwilk012]

I had a plastic bumper and am following those directions. First question is how did you route the wiring harness for the fog lights?

Second question: How did you install the frame doubler plate? It says put in bolts but never references nuts or torquing them down.

Third question: Where the hell is the frame support gussets? The step says to remove two nuts holding the frame support gussets. The picture makes no sense to me.

Fourth question: Did you trim both sides of your frame rails to fit a zeon winch?

Please help!

I just installed mine yesterday yesterday but used a VR series winch so I cannot answer question 4, however:

1. Route it straight across the back side of the bumper, just stick a few of the original clips on the bumper as you go.

2. Skip this step. Seriously don’t bother doing it until you are installing the support brackets for the winch plate. The doubler plate will go inside of the frame rail, with the bolts inserted from the inside of the bracket and frame rail, where you will the install the flanged nuts.

3. The side of the frame rails have two support brackets that look like they don’t do anything at all. This step is real and has to be done. There are 4 frame support gussets total, one on each side of the 2 frame rails. Take out the one single bolt.

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