Every now and then a company takes an old product and reinvents it in a way that just makes sense. Recently American Expedition Vehicles (AEV) did just that by presenting its new stamped front bumper for Jeep JK Wranglers. You might think that a bumper is a bumper, but what sets this one apart is that it is produced through a stamping technique. Stampings are done with a massive machine that pinches a sheet of flat steel between two molded dies, resulting in a three-dimensional piece. This is how many body panels for automobiles are made, and AEV simply applied this same procedure to some 1/8-inch-thick steel and formed a very fluid-shaped front winch bumper, which when stamped can be as strong as a 1/4-inch flat-plate bumper.
Don't think this is simply another glamour product for the all-show, no-go Jeeps. In addition to the stamped front section that has many of the same contours and accents of the factory body lines, AEV also added details such as a 3-inch tubular grilleguard, 1/4-inch-thick winch-mounting plate, tow hoops, and crush cans that protect against unwanted airbag deployment at low speeds. Unfortunately the process of stamping requires intensive engineering and then costly tooling when setting up the massive dies, which can result in premium pricing (roughly $1,300). However, the end product definitely is a top-shelf unit and makes other bent tube or folded plate bumpers seem a bit lackluster.
We like to think of bumpers similar to sneakers. In the performance spectrum there are many different options, but for the most part it comes down to what styles you like best. The new stamped bumper by American Expedition Vehicles is definitely unique in the bumper market. | 
AEV does all of its engineering with computer-aided design, and this is especially important when developing a stamped part. Since the stamping process is done with an expensive die, going back and making changes after the fact can be costly. So as much research as possible is done prior to the first stamped prototype. This allowed AEV to adjust contours and dimension, better accommodate a winch, and offer clearance for front tire and approach angles while still safely protecting the body and frame. | 
Once the old bumper is removed, you can start installing the AEV parts, first attaching the 1/4-inch winch-mounting plate and 3/16-inch fairlead mount. Along the side of the frame are the 1/2-inch tow loops. These are your recovery points, and they can accommodate the towbars offered by Mopar. Since they have additional 1/4-inch steel reinforcements, there is no concern for your Jeep breaking loose from behind your motorhome. |
The Jeep frame comes with crush cans that are intended to collapse during a low-speed fender bender before the full bumper and frame take a hit, and this adds a buffer zone before the airbags are activated. AEV considered this a well engineered safeguard and left openings in the stamped bumper for the crush cans to protrude. However, to clean them up a bit, textured polyethylene caps are used that blend in better with the bumper's blueprint. | 
With the bumper installed, you can see how the stamping flows and has handsome indentions in front of the turn signals. The outer ends of the bumper allow for an improved approach angle versus the factory bumper, while still protecting the flexible-yet expensive to replace-plastic fenders. The factory front bumper foglights will easily install into the bumper openings. There are also additional mounts above the winch for auxiliary off-road lights. The winch opening is capable of holding most winches up to 9,500 pounds-though some slight trimming may be required-but it cannot fit the Warn Powerplant or 8274 units. | 
In order to protect the steering box as well as the electronic sway-bar disconnect available with Rubicon package JKs, AEV also offers a skidplate that wraps underneath the bumper and front framerails. The skidplate is also made of 1/8-inch steel and has openings for use with a Hi-Lift Jack. Like the bumper, it has an electro coating, zinc coating, and powdercoating for a long-lasting rust-inhibitive finish and can install with just basic handtools, a drill, and some drill bits. |