Falken Fabrication DIY XJ Front Bumper - Jeep XJ

The DIY XJ Front Bumper for the Jeep XJ is a collaboration with Recon Expedition, hence the name. A little bird told us that Robin was planning an XJ-based overland build, and it didn’t take long before the plans for a front bumper began to take shape.

Don’t miss Robin’s excellent How-To video:

https://www.youtube.com/watch?v=0fcUu7lMkpY

When we started working on the design that would become the Falken Fabrication DIY Recon Edition Front Bumper, we set the bar as high as we possibly could. The goal was to offer a product that is better-looking, stronger, and easier to assemble than what our competitors provide.

To begin with, we chose to build it from an extremely high-strength steel — especially compared to what American brands typically use. The common steel grade among our competitors is S185, while ours is built from Swedish S355 specialty steel from SSAB. As a result, we could use slightly thinner plates, saving weight without compromising strength.

The steel and the internal reinforcements inside the structure ensure that the bumper protects the Jeep’s weaker components and holds up to serious off-roading — whether it’s contact with the ground or heavy winching. The design also provides one of the best approach angles on the market, which does wonders for how the Jeep handles rocky terrain.

Aesthetically, the goal was to create a product that doesn’t look home-built. Once welded together, the finished bumper should look like it could just as well have been built professionally in a factory — something not all of our competitors can claim.

The design is as slim as possible. Our aim was to create a bumper that fits the XJ’s design language without the “chin” that many winch bumpers for the model tend to have.

The product is delivered as a flat-pack kit with pre-cut plates. Each plate has reliefs for all bends, meaning the only tools needed are pliers, a workbench, and a couple of clamps. The instructions show the degree of each bend, and the different parts can also be used to confirm that everything is aligned correctly. Once all parts are bent, they are tack-welded together, test-fitted on the Jeep, and then fully welded. After welding, all that remains is grinding and painting.

• Complete DIY kit assembled using a welder, an angle grinder with flap disc, and simple hand tools.

• Full S355 steel construction: 4 mm bumper plates and 15 mm shackle tabs.

• Internal reinforcements for the skid and winch plate.

• Class-leading approach angle.

• Space for the most common winches on the market.

• Total weight approx. 35 kg.

The product is made to order with a lead time of about one week.