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  Top » Catalog » Project Baja Bug » Project Baja Bug Page ,28 Installing the Rear Bumper and Tail Li
      
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It is time to get the rear bumper on. A standard firewall rear bumper will not work on this car since we wanted our bumper to bolt directly into the roll cage. So it's time to modify.

I really like the look of the double tube rear bumpers, but we had a problem getting it to connect to the rear of the roll cage. So we had to cut off the bars that would have attached to the fire wall. The bottom off the bumper will still mount to the horn bolts.


We also decided that we wanted the upper support bar to mount to the bottom cross tube instead of the top one.


These bumpers take a small amount of tweaking to get them straight. First we attached the bottom bars to the horn bolts and tapped it back and forth until it looked straight with the firewall.



Steve had cut the new cross bars and had to put a slight bend on each side and notch the ends. While he was welding on the bars, I removed the remains of the old ones we had already cut off.


Next we need to put on the light tabs. We will run two lights on each side a turn signal on the outside and brake/tail lights on the inside.


Fairly simple, even for me to get these tabs even and level on both sides. Jackson and Steve quietly towered over me to make sure I was doing this correctly.   



OK, our tabs are welded on so it is time to primer and paint.


We choose just to paint the rear bumper black like the side bars. Before we put in the Red tail lights, we have to open up the holes in the tabs a little. It was a very small amount the we drill out so the lights would slide in.


As you ca see from the photo, these tail lights have a chrome back to them. We will be putting on four total red lights on the bumper.


Our plan is to have the two outer lights as the turn signals and the two inner as brake/tail lights. So then Jackson walks up and asks me where the license plate mount is going to go? So we had to sand down two small section to weld on two tabs on the freshly painted bumper.



Using an old license plate to line up the tabs, we started welding.


After the tabs cooled down, I grabbed Mr. spray paint can and touched up my screw up. Steve, our new guy said the from a distance you can't even tell.


Ok, we now have our turn signals, tail lights and license plate mount that has a light. Soon I hope we can get this car wired. Next we will do the front lights.

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This article was published on Wednesday 11 July, 2007.
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