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XJ40 replacement bumper options

carlmt
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Location: Redditch, Worcestershire

Re: XJ40 replacement bumper options

Postby carlmt » Tue Aug 08, 2017 4:32 pm

A very tidy - and original - idea Clive. It seems to tick all the boxes for the ideas you had originally.

Were I to go along this road - and you say that the beams are fabricated on a bespoke basis - I would certainly have the side extensions, tapering much as the originals do.
Additionally, I dont think it would be beyond the realms of impossibility to have the original front and rear light units housed in 'in bumper' boxes as opposed to hanging beneath. Especially those front units - they look vulnerable to me. If mine, I would also extend the top surface to further close the gap between the bumper and the bodywork.

Just my views!! Otherwise, a great effort and solution to the problem - well done!

CT 8-)
1990 Daimler 4.0 638778
First registered 01.01.1991
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carlmt
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Joined: Sat Jan 02, 2016 11:44 am
Location: Redditch, Worcestershire

Re: XJ40 replacement bumper options

Postby carlmt » Tue Aug 08, 2017 4:39 pm

NMV 1E wrote:I'm very impressed with these, I really am. Well done to you sir. Though, the rear fog lamps also include the rear reflectors (?). We're almost neighbours by the way.


That is a very valid point!!! Technically, your car doesn't conform to The Road Vehicles (Construction and Use) Regulations 1986 without the reflectors.
Whether this will ever be picked up by the MOT, I don't know, but I am sure that it IS an MOT-able item.

CT 8-)
1990 Daimler 4.0 638778
First registered 01.01.1991
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SovverBovver
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Re: XJ40 replacement bumper options

Postby SovverBovver » Tue Aug 08, 2017 10:16 pm

Clive Aintree wrote:I have replaced the in-bumper rear fog lights with proprietary stainless-steel items and am currently working on something similar for the front side/indicators.



The advice above about reflectors is correct. I'm certain a car has to have reflectors fitted on the rear to be legal to use on UK roads. They should be checked as part of the Mot test. I'd also worry about whether an insurer would quibble about liability if these were not fitted to a car involved in a night time accident.

I like the idea of these all metal bumpers as an alternative to keeping the original ones on my Jag which people round here would just end up damaging. Those side pieces can be broken so easily they're almost unfit for purpose and when an XJ40 has tatty bumpers they really let the car down. People hitting other cars is such a big problem round here, I've stopped using my Jag for local trips. The bumpers on these cars are really easy to remove, so you could keep the originals and get a set of stainless ones changing them depending on what duties the car has ahead of it.

I don't know why manufacturers make bumpers that can be damaged after a small impact. When I go to the supermarket, I use my other car because it's got large steel bumpers and a hitch fitted at a much higher level than most cars so it doesn't get damaged. However, it still annoys me when I see a car parked 2 inches away from my bumper, or someone tells me they saw it get hit. Once I even had an old man tell me there was no contest between his car and mine. He then proceeded to demonstrate how flexible his painted bumper was by deforming it excessively with his hand. He then wanted to strike up a conversation with me about my car and his previous cars! A woman who hit my car (while someone was in it) obviously had no concerns whatsoever about bumping into another car, and obviously couldn't care less that she'd just damaged her reasonably new Audi.
1992 Jaguar Sovereign

Clive Aintree
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Re: XJ40 replacement bumper options

Postby Clive Aintree » Wed Aug 09, 2017 1:03 pm

Many thanks for all your interesting and supportive comments. The matter of the reflectors will be urgently looked into - I certainly don't want the car rammed in the rear at night! I assumed that the main rear lamp clusters had built-in reflectors and that the bumper ones were just additional but apparently not?

The front lamp units shown are temporary ones just to pass the MOT, actually farm tractor units! The firm who did the bumpers have mentioned making stainless housings for these to go into. I'm also looking at options such as a "square" (rectangular actually) stainless spot lamp units each with two bulbs - one white, one amber. Some owners might even opt to have lights units built into the new bumpers, just a matter of making cut-outs. But I didn't want to make holes in my nice new bumpers!

This is still very much a work in progress. Though at present each additional one will be "tailor made", generic versions might follow if there is sufficient demand. Another serious suggestion is that the stainless bumpers could be fitted to save deterioration of the the original steel-cored rubber ones which could be preserved for shows or maybe only fitted during the summer months. (The stainless ones can be removed in 5 minutes or less - just the two M12 bolts reached via access cut-outs in the underside of the bumper.)

So thanks again for all your contributions.

Clive
Clive

XJ6 3.2 1992
Land Rover Freelander TD4 2005
Austin A30 1955
Honda CB400A 1980

abercanadian
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Re: XJ40 replacement bumper options

Postby abercanadian » Wed Aug 09, 2017 5:59 pm

Clive -
If you cut lamp apertures into the bumper they won't have to be too special ...the lamp housings themselves have spring clips at either end and are simple push-fits into the bumper - of course the apertures are recessed with the standard setup, the recess being "provided" by the additional thickness of the rubber.

Cheers

Larry
94 XJ40 VDP vin 701729
Oyster Metallic/Doeskin on Aero Alloys
240,000 km/149,000 Miles
Daily Driver

94 XJ40 SOVEREIGN vin 703632
Diamond Blue Metallic/Barley
111,000 km/69,000 Miles
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Clive Aintree
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Re: XJ40 replacement bumper options

Postby Clive Aintree » Tue Apr 27, 2021 6:22 pm

Hi folks - an update on this 2017 thread. For the full story and new photos please check out this Jag Lovers thread - a UK supplier showing interest in remanufacture:-

https://forums.jag-lovers.com/t/remanuf ... ers/405730

And we may need a North of England XJ40 owner to help develop.

All the best and keep safe,

Clive
Clive

XJ6 3.2 1992
Land Rover Freelander TD4 2005
Austin A30 1955
Honda CB400A 1980

Aidan
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Joined: Fri Jun 26, 2009 11:57 am
Location: Tonbridge, Kent

Re: XJ40 replacement bumper options

Postby Aidan » Thu Apr 29, 2021 8:51 pm

Clive Aintree wrote:Hi folks - an update on this 2017 thread. For the full story and new photos please check out this Jag Lovers thread - a UK supplier showing interest in remanufacture:-

https://forums.jag-lovers.com/t/remanuf ... ers/405730

And we may need a North of England XJ40 owner to help develop.

All the best and keep safe,

Clive


Hello Clive,

This sounds exciting, and thank you for initiating this project. My car will need some sort of bumper rebuild work in the near future and I was day-dreaming of welding-up a new metal structural beam for my car - assuming it's original units were toast - even though I can't weld :lol: :oops:

I read your Jag-Lover's posts and it sounds as if things are progressing well.
I'm wondering if your intention is to produce an item that, while not fabricated the same way as the original, (your welded stainless steel "box beam" vs. Jaguar's mild steel rust trap ;)), it would still look the same from the outside? So it would have the same tapers and radii to the visible parts of the brightwork and the same depression in front of the grille etc, and the rubber elements would be held onto the outside of the beam via some sort of secret fixing/clip arrangement?

Another thought is that, while it's probably desirable to fabricate the bumbers out of as few a number of pieces as possible, doesn't that method mean that even a small nudge to one part of the bumper would possibly render the whole thing in need of replacement due to ripples and dents in what is essentially a single piece of metal? If I may contribute an idea to this really useful project, would it perhaps work out better to have three box sections per bumper; one central and two corners, so that a bash to one third wouldn't mean the whole unit needs to be replaced? I imagine that once a jig was made there might not be too much more work involved for the fabricators to make a bumper out of three smaller sections which could then be bolted together somehow whilst fitting it to the car?

If this is of interest to you, I could sketch something to give you a better idea of what my thoughts are so you and the fabricators could more easily abandon my idea or run with it and refine it?

Regards
Aidan

1994 Moroccan Red XJ40 3,2 Sport ("Ruby")
1995 Jade Green X300 3,2 Sovereign ("Jade")
2005 Cedar Green Pearl Volvo XC 90 SE - Sold
2007 Colorado Red Ford Galaxy Ghia

Clive Aintree
Posts: 53
Joined: Wed Apr 29, 2015 6:14 pm

Re: XJ40 replacement bumper options

Postby Clive Aintree » Fri Apr 30, 2021 12:12 pm

Hi Aiden,

Many thanks indeed for your feedback and ideas. Back in 2017 I found myself in the same position as you, bumper crumbling and frankly sick of scouring scrapyards for replacements which would just rust out again. My first idea was to convert to XJ6 Series 3 bumpers. What particularly appealed was the easy availability of stainless copies for example from Harrington:-

https://groupharrington.com/product/jag ... 2-bumpers/

If they had been a straight fit, I would have shelled out the cash. But if they had to be butchered to fit, it would probably be easier to scratch built for the XJ40. That is how I came to design and have made something that was basic but attractive. If I were to make another, I would copy the profile of the original rubber versions, probably build in the lights and if the buyer requested it, add rubber facing.

This corrosion is never likely to be a problem for cars from dry climates or which are garaged. But for my street parked UK car chasing bumper corrosion was going to be an ongoing chore. Some UK XJ40 owners who saw my bumpers were actually thinking of removing their rubber originals and only re-fitting them for shows or maybe the summer like in some countries cars have sets of summer/winter tyres.

If the demand is low, it might just be a question of bumpers being made to special order by the firm in Liverpool that I used, Leeming Murphy. Then owners could pick the shape, size, lighting options etc.
Clive

XJ6 3.2 1992
Land Rover Freelander TD4 2005
Austin A30 1955
Honda CB400A 1980

Clive Aintree
Posts: 53
Joined: Wed Apr 29, 2015 6:14 pm

Re: XJ40 replacement bumper options

Postby Clive Aintree » Fri Apr 30, 2021 12:35 pm

Hi Aiden,

Following on from your suggestions as to construction, I would probably opt for single piece using again flat laser cut top/bottom plates with flat front fillers but reduced here to a slimmer 75mm/3" rather than my prototype 100mm/4" height. As to separate side extensions, these really might only needed in my view at the back where they are longest. But making them separately would probably increase the cost. Repairing these bumpers would generally be very easy anyway for firms used to doing fabrication work. And I can tell you that it is very difficult to dent 1.5mm stainless plate - hammers bounce off it!

It would definitely be a good idea to have the long rear side extensions made with lugs to clip onto body mounts. They would need support here in case kiddies climbed onto the bumpers etc.

At the rear, I would probably just fit after market fog warning lights again. At the front, building in the original side/turn lights would probably be better.

Certainly post any design ideas.

Keep safe,

Clive
Clive

XJ6 3.2 1992
Land Rover Freelander TD4 2005
Austin A30 1955
Honda CB400A 1980


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