The winch bumper project ('cause I needed another project)

[fishsticks]

It's been raining a lot here lately, and since my garage is perpetually full of crap that means I don't tinker on the truck as much as I'd like. I still need to put in my front gears. Sigh.

I had a couple hours free yesterday. I also had a winch and winch plate sitting in my garage. See where this is going? No?

I'll let the pictures tell the story. (Sorry, gray day made the pics overexpose a bit)


Grinder masasaging:






Nice and tight:










I have a few more pics...but these get the idea across. The winch plate is 1/4" bent steel and costs $40 from Harbor Freight... which is coincidentally where the winch is from. I had to drill two new holes to match our bumper bolts and modify the solenoid box a little to get things to fit nicely. Going to bend some tube around this whole contraption and try to tie in where the stock swaybar used to be. For now it stays ugly...

Now I need a top post battery.

[Trail X]

Me likie.

It should be fine for inline pulls... but I worry about any up or down pulls. It will create a large moment on your winch plate and could bend it up or down. Might want to buttress it to the bottom of the frame... or get two bolts per side on that plate.

[bartonmd]

Me likie.

It should be fine for inline pulls... but I worry about any up or down pulls. It will create a large moment on your winch plate and could bend it up or down. Might want to buttress it to the bottom of the frame... or get two bolts per side on that plate.

Exactly!

I'd just get some 1/4" or 3/16" plate, and weld a vertical piece onto the bottom of your winch plate, then a horizontal piece going back under the bumper (basically making a "C"); and run your bumper bolts through it on both top and bottom of the frame... done.

Or, not quite as strong, but I'd at least weld the winch plate to the bumper, as far forward as you can, and as much linear weld as you can... Like seam weld the top front edge of the bumper with wherever that meets the bottom of the winch plate...

Mike

[fishsticks]

My thought was actually to weld a tube horizontally under the front of the winch plate and weld that to the stock bumper. Then use that tube as a base to weld in vertical tubing, either to tie into or replace the ghetto radiator skid. Also I have free mount points where my swaybar used to be... and six frame attachment points would please me... thoughts?

[bartonmd]

My thought was actually to weld a tube horizontally under the front of the winch plate and weld that to the stock bumper.

Same point, really... I like it...

[/quote] Then use that tube as a base to weld in vertical tubing, either to tie into or replace the ghetto radiator skid. Also I have free mount points where my swaybar used to be... and six frame attachment points would please me... thoughts?[/quote]

I suggest not putting your radiator skid in front of your bumper (meeting said tube from above)... You want to be able to leave the radiator skid in place while removing the oil pan skid and bumper, because you'll have to remove those a lot more often than removing the radiator skid...

Mike

[DmccartneyFF2TB]

OOOOOO I likey.

[fishsticks]

I suggest not putting your radiator skid in front of your bumper (meeting said tube from above)... You want to be able to leave the radiator skid in place while removing the oil pan skid and bumper, because you'll have to remove those a lot more often than removing the radiator skid...

Mike

Point taken. There are a few things I have to think out...like how I can continue to access the front winch bolts. They are actually outside the stock bumper. Also coming around from the side and mounting to the swaybar mounts would make the bumper difficult to pull off from the front. I'd have to pull it forward, then down.

I've been reading Pirate too much lately, and it's put ideas in my head. Someday I may exo the entire truck, so I want to do this once and have it be strong. Then I can build off of it in the future.

[janesy86]

Not too shabby.

[HARDTRAILZ]

Exo is cheaper, but i think the sas is needed for function first.

[fishsticks]

Exo is cheaper, but i think the sas is needed for function first.

I know I know. I'm trying to avoid the SAS bug... but I'm inching closer. I think not installing the front 4.56 gears may be my subconscious wanting to SAS.

I can't afford it. I need to keep telling myself that.

[HARDTRAILZ]

my front end is literally falling apart and it is really hard to justify putting any money in it when I know i want a sas. drivers seal leaks bad enough it shows on the ground, log took out boot on pass half shaft, splined disco had mind of its own and needs welded.
Prolly will fix it and try 35s to see if it satisfies,,,but you know how it is..

[MrSmithsTB]

my front end is literally falling apart and it is really hard to justify putting any money in it when I know i want a sas. drivers seal leaks bad enough it shows on the ground, log took out boot on pass half shaft, splined disco had mind of its own and needs welded.
Prolly will fix it and try 35s to see if it satisfies,,,but you know how it is..

I know how you feel. I'll have mine paid off in a few months, then I have some pretty wicked plans.

[bartonmd]

Frankly, I suggest doing a radator skid like I make... If you want the extra support from another hole in the frame, box the sides of the rad skid... I don't do it because it would collect mud and stuff, but it would add strength...

Mike

[fishsticks]

Frankly, I suggest doing a radator skid like I make... If you want the extra support from another hole in the frame, box the sides of the rad skid... I don't do it because it would collect mud and stuff, but it would add strength...

Mike

Do want.

Hate shipping.

[fishsticks]

So I worked on this some today.

The first piece of my new bumper. Submitted for critique/suggestion. I ran out of hands/jackstands/pieces of wood to hold the thing in place, so it's crooked. But you get the idea. The wings actually do line up with the front of the fender when it's in the proper spot.







Cosmetically it's meh... especially in this picture (it actually looks better in person). Primary concern is fender/body protection

Originally I planned on tying the wings directly to the top of the winch plate via miter cut/weld. I bent a 3' piece on one side as a template first and decided I liked it under the winch plate. The winch plate itself is going to be tied to the stock bumper with 3/16" angle steel.

Right now I'm thinking about a bar which goes over the winch to tie the two wings together and then some triangulating pieces welded to the winch plate.


I'm open to all suggestions, cosmetic and structural. I'm also open to "throw it out and start over."

Oh, and I'm using ASTM A53A pipe. Let the flaming begin.

[Trail X]

Do they tie into sliders? You definitely need some triangulation pieces, otherwise they won't protect you from anything.

Also seems a bit low over the wheel well opening... shouldn't they run along the top of the wheel arch?

Or are you going for the handlebar mustache look?

[bartonmd]

Do they tie into sliders? You definitely need some triangulation pieces, otherwise they won't protect you from anything.

Also seems a bit low over the wheel well opening... shouldn't they run along the top of the wheel arch?

Or are you going for the handlebar mustache look?

I think he just hasn't cut the ends off, yet...

Mike

[fishsticks]

Yep, I'll cut them off before the arch once I get the whole contraption welded into place. Yesterday I spent a couple hours with the bender just getting things right. Coumpound bends are kinda hard.

This is just the first piece. I quit yesterday after the metal informed me it was tired of being worked. It did this by cutting my thumb open.

I need to cut a lot of material off the sides of the stock support still as well...

[Saxis]

Frankly, I suggest doing a radator skid like I make... If you want the extra support from another hole in the frame, box the sides of the rad skid... I don't do it because it would collect mud and stuff, but it would add strength...

Mike

Do want.

Hate shipping.

Hmm... If you're seriously looking at buying a Rad Skid, maybe we could have a couple shipped together to save a bit. You're only a couple hours away from me, and I'd like to get skids by next summer. (Hoping I can still get a v8 oil pan skid also.) Might be able to find a couple others as well...?

[fishsticks]

Progress!




Basic shape done... need to add some supports now.