AEV Front Bumper Released For JT Gladiator!

[Johnny3]

This thread inspired me to put an AEV JK Premium bumper on my Gladiator... I bought the bumper DIRT cheap on Facebook MP (was a little rough) and refinished it using the exact same process as @2020 SCRAMBLER did here.

I purchased a new AEV JL/JT winch mount plate as well as a new AEV JL/JT RX/EX bumper front skid plate... these are sold separately from the RX/EX front bumper.

I eliminated the crush cans, replacing them with TeraFlex D-Ring mounts, which allowed me to leave off the AEV recovery points (rather than modify the JK version or the skid plate). I mounted some BD LP6s on the bumper hoop (in the same upside down manner as the EX/RX bumper does), using steel brackets I got on Amazon. I also mounted a Warn Zeon 10S Platinum. The clearance is TIGHT, but its not touching the bumper, once I put the spacers in.

It all fits (tight to get on but it fits) on the Gladiator with a) some very minor trimming of the JK bumper's fairlead bracket and, b) a 1" spacer between the frame ends and the JK bumper's fairlead bracket.

Im going to do a build thread to document it and answer any questions, but I thought I would post a pic and say thanks for the inspiration. I also wanted to highlight for @Montana Brian that you can mount a winch without DV8 or other brackets. These are essentially just spacers anyway.

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[Montana Brian]

Thank you for the update on the winch mounting! How well does the winch clear the bumper when installed?

 

[Johnny3]

Thank you for the update on the winch mounting! How well does the winch clear the bumper when installed?

It barely clears, perhaps by a quarter inch or so, between the top lip of the winch opening and the crown of the winch... but thats the idea. There is plenty of room everywhere else, including inside the bumper. Ill take more detailed photos for a separate thread.

***special note: this is a ZEON PLATINUM winch, which has a wireless controller. It doesn't have a clutch lever or the need to plug in a controller. I think makes a big difference in this application, which is tight.

 

[2020 SCRAMBLER]

@Johnny3 really, really nice job on the JK bumper and winch install!

I’m finally getting around to installing a winch @Montana Brian!

So, I went with the Warn VR Evo 12-S winch. Certainly not the cheapest option, but I felt for a name brand winch, 12,000 lb (actual) rated capacity, synthetic rope, wire controller, and aluminum fairlead for <$1K it was reasonable and delivered to my doorstep in less than 48 hours.

The VR Evo 12-S basically fits the AEV JK bumper:

• plenty of room to spare on the sides of the winch bay
  
  
• barely fits on the front edge of the bumper (maybe 1/4” of clearance around the control module)
  
  
• does not quite fit on the backside of the winch bay area without trimming the bottom of the 7 slot grill panel (the control module that sits on top of the winch has 3 wires coming out of the back that press against the lower portion of the grill panel)

The lack of the control module wires on the winch @Johnny3 used is likely the reason his winch cleared the grill and mine did not.

While I don’t like trimming the grill panel, the VR Evo 12-S is $900 compared to the Zeon Platnium 12-S at $2,300. For a $1,400 savings, I’ll live with the grille trimming and a wired remote.

But, accessing the VR Evo 12-S clutch lever is going to be an issue with my current driving light installation. This is due to the AEV JK bumper mounting extra lights on a bracket bolted to the top of the bumper. While I might be able to install the bracket 180* that will push the light housing location forward and out.

@Johnny3 can you link me to the Amazon brackets you used to mount the lights on the bumper hoop?

Also, I think the solution @Johnny3 devised to REMOVE the AEV crush cans and plastic bumperettes and instead install Terraflex D-ring mounts is BRILLIANT! That is the most simple, clean, least effort, and cost effective way to have stout front tow hooks with the AEV JK bumper on a JL/JT.

Here’s why:

• the AEV JK bumper bolts up where the factory tow hooks are located, so the OEM JL/JT tow hooks are not an option
  
  
• the AEV JK bumpers included a set of tow hooks EXCEPT for the bumpers sold as part of the Jeep JK Call of Duty option package (of course that’s my version of this bumper…and AEV only sells the JK tow hooks as part of a $500 con-box group of parts…it took me two years to locate a pair of new AEV JK tow hooks on eBay for $50)
  
  HOWEVER the JK AEV tow hooks do NOT not just bolt up to the JL/JT frame; if you want the JK tow hooks to work on a JL/JT you MUST modifying the hook (cutting and welding) which is the cleanest AEV looking install AND would allow the tow hook to fit properly with the AEV skidplate
  
  
• the Warn JL/JT Recovery Hooks (very stout and very expensive at $300 new BTW) are a good option for tow hooks like @Montana Brian used; I’d located a used pair 4 years ago (also on eBay for maybe $75); these could be used with the AEV JK skidplate but requires trimming on the outside edges of the skidplate like @Montana Brian did to fit; the Warn tow hooks will NOT work with the Rubicon skidplate as Warn uses the same frame holes as the OEM Rubicon skidplate brackets

AEV JK bumper exploded parts diagram:

I’ll post again with more info and pictures when I’m done with the install.

 

[2020 SCRAMBLER]

Oh, @Johnny3 the AEV JL/JT RX/EX bumper front skid plate…can you show some up close photos of it?

Especially the front top leading edge of the skidplate where it meets the underside of the AEV bumper.

My guess is it just mounts to the vertical JT frame horn extensions like the OEM Rubicon skidplate? And it doesn’t attach to the underside of
AEV JK bumper?

AEV JL/JT RX/EX skid plate:

 

[Montana Brian]

@Johnny3 really, really nice job on the JK bumper and winch install!

I’m finally getting around to installing a winch @Montana Brian!

So, I went with the Warn VR Evo 12-S winch. Certainly not the cheapest option, but I felt for a name brand winch, 12,000 lb (actual) rated capacity, synthetic rope, wire controller, and aluminum fairlead for <$1K it was reasonable and delivered to my doorstep in less than 48 hours.

The VR Evo 12-S basically fits the AEV JK bumper:

• plenty of room to spare on the sides of the winch bay
  
  
• barely fits on the front edge of the bumper (maybe 1/4” of clearance around the control module)
  
  
• does not quite fit on the backside of the winch bay area without trimming the bottom of the 7 slot grill panel (the control module that sits on top of the winch has 3 wires coming out of the back that press against the lower portion of the grill panel)

The lack of the control module wires on the winch @Johnny3 used is likely the reason his winch cleared the grill and mine did not.

While I don’t like trimming the grill panel, the VR Evo 12-S is $900 compared to the Zeon Platnium 12-S at $2,300. For a $1,400 savings, I’ll live with the grille trimming and a wired remote.

But, accessing the VR Evo 12-S clutch lever is going to be an issue with my current driving light installation. This is due to the AEV JK bumper mounting extra lights on a bracket bolted to the top of the bumper. While I might be able to install the bracket 180* that will push the light hosing location forward and out.

@Johnny3 can you link me to the Amazon brackets you used to mount the lights on the bumper hoop?

Also, I think the solution @Johnny3 devised to REMOVE the AEV crush cans and plastic bumperettes and instead install Terraflex D-ring mounts is BRILLIANT! That is the most simple, clean, least effort, and cost effective way to have stout front tow hooks with the AEV JK bumper on a JL/JT.

Here’s why:

• the AEV JK bumper bolts up where the factory tow hooks are located, so the OEM JL/JT tow hooks are not an option
  
  
• the AEV JK bumpers included a set of tow hooks EXCEPT for the bumpers sold as part of the Jeep JK Call of Duty option package (of course that’s my version of this bumper…and AEV only sells the JK tow hooks as part of a $500 con-box group of parts…it took me two years to locate a pair of new AEV JK tow hooks on eBay for $50)
  
  HOWEVER the JK AEV tow hooks do NOT not just bolt up to the JL/JT frame; if you want the JK tow hooks to work on a JL/JT you MUST modifying the hook (cutting and welding) which is the cleanest AEV looking install AND would allow the tow hook to fit properly with the AEV skidplate
  
  
• the Warn JL/JT Recovery Hooks (very stout and very expensive at $300 new BTW) are a good option for tow hooks like @Montana Brian used; I’d located a used pair 4 years ago (also on eBay for maybe $75); these could be used with the AEV JK skidplate but requires trimming on the outside edges of the skidplate like @Montana Brian did to fit; the Warn tow hooks will NOT work with the Rubicon skidplate as Warn uses the same frame holes as the OEM Rubicon skidplate brackets

AEV JK bumper exploded parts diagram:

I’ll post again with more info and pictures when I’m done with the install.

Thank you for the detailed pic! Before long I'll be trying to install a winch plate that a friend gave me. It's not an AEV, he bought it for his Rubicon 392, but decided he didn't want to do a winch on it about 6 months after he got the plate, so couldn't return it.

I'm thinking I might make some custom spacers to get the bumper to line up with the fender properly once I see how it all fits together

 

[2020 SCRAMBLER]

No problem @Montana Brian. This has turned into a bit of a quest for me…lol.

A non-AEV winch plate likely works but you’re almost certainly in for some fabrication to get it all to play together.

Do you not have the parts labeled “fairlead bracket” and “winch plate” (in the exploded pic view) that came with your AEV bumper?

Those two parts bolt together into a “L” shape to hold the winch and then the bumper is bolted on through the fairlead bracket directly to the frame horns. Had to use a floor jack to support the winch plate, fairlead bracket, and winch while I lined up and bolted on the bumper.

Everything had to be bolted together loose as there almost zero tolerance available to shift things around…

…and I had to use thick metal shims (scavenged control arm bushing washers from another project) to avoid my winch plate being on a slight down and forward sloped angle when bolted together.

And you do know the AEV JK bumper never fully lined up with the JK fenders, right?

If you have the Gladiator Rubicon high fenders, it makes the gap even larger than non-Rubicon/Mojave fenders. There’s a cheap plastic insert the Gladiator and Wrangler Sports (and all export models) used to have installed by the factory that closed that gap. You might trying finding a set of those to save the extra fab work as most guys remove them when upgrading bumper and/or wheels and tires. The AEV JK bumper looks fine to me on the JT with the space as-is so I’m not bothering with that aspect.

 

[Montana Brian]

No problem @Montana Brian. This has turned into a bit of a quest for me…lol.

A non-AEV winch plate likely works but you’re almost certainly in for some fabrication to get it all to play together.

Do you not have the parts labeled “fairlead bracket” and “winch plate” (in the exploded pic view) that came with your AEV bumper?

Those two parts bolt together into a “L” shape to hold the winch and then the bumper is bolted on through the fairlead bracket directly to the frame horns. Had to use a floor jack to support the winch plate, fairlead bracket, and winch while I lined up and bolted on the bumper.

Everything had to be bolted together loose as there almost zero tolerance available to shift things around…

…and I had to use thick metal shims (scavenged control arm bushing washers from another project) to avoid my winch plate being on a slight down and forward sloped angle when bolted together.

And you do know the AEV JK bumper never fully lined up with the JK fenders, right?

If you have the Gladiator Rubicon high fenders, it makes the gap even larger than non-Rubicon/Mojave fenders. There’s a cheap plastic insert the Gladiator and Wrangler Sports (and all export models) used to have installed by the factory that closed that gap. You might trying finding a set of those to save the extra fab work as most guys remove them when upgrading bumper and/or wheels and tires. The AEV JK bumper looks fine to me on the JT with the space as-is so I’m not bothering with that aspect.

I didn't know that it didn't fit the JK well. This Gladiator is a sport a Willys.

As far as I know, the winch Mount has those sorts of parts, designed to work with stock steel bumper for the 392 Rubicon, which I think is made (or at least designed) by AEV. Still trying to get much needed repairs and maintenance done on my JK, so I'm not sure when I'll get to the JT.

 

[2020 SCRAMBLER]

@Montana Brian if you have the AEV parts in the exploded diagram, I don’t think you need the 392 winch plate as it would be duplicative with the AEV parts…but if the 392 plate is in fact an AEV part you may have the same winch plate as @Johnny3.

And I don’t think you’ll be able to space UP the AEV bumper as the fairlead openings on the bumper and fairlead bracket will no longer line up and your AEV skidplate would no longer fit too. You can obviously space it OUT (forward) like you did, but doing so does slightly decrease your approach angle.

 

[2020 SCRAMBLER]

In case anyone is looking for one of these AEV bumpers here’s one a dismantling yard is asking $850. I’d offer less as it needs a little bit of refinishing. Set of parts looks complete.

AEV JK Call of Duty bumper on eBay

 

[2020 SCRAMBLER]

Alright, I’m finally done installing the entire AEV JK bumper, winch plate, skid plate, and recovery hooks…with a Warn winch!

A former forum member @ArcaneJohnWayne sent me this photo showing how he used angle steel to create the skid plate cross-support:

In addition to taking this approach to creating a cross member, we also trimmed a small amount off the bottom of my frame extensions (that hang down) so that they are now parallel to the ground.

The recovery loops needed the most fabrication and required welding, so that job was outsourced to a professional at a local Overland shop. Essentially the flat plate on the front of the recovery loop was cut off and then re-welded at the correct angle and a hole drilled to match the factory hole in the frame horn.

The fabricator also did some mild trimming of the skid plate to accommodate a wrench accessing the front most bolt securing the modified AEV recovery loop.

Completed photos:

Absolutely LOVE the way it all turned out. Very factory / AEV in appearance.

And I did not have to relocate the brackets for my driving lights as I can still access the clutch knob on the winch.

BUT, if I had to do again I’d go the route of @Johnny3 and cut off the JK bumper crush cans and install 2 plates at the frame bolts for recovery loops as that is a MUCH more simple installation with limited driveway fabrication required.

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