Winch bumper Build

[KZ750]

Here are some pictures of my build. Feel free to ask any questions, and I'll be happy to answer.
I still have a couple things left to do, like add four more bolts to the bumper mounts, weld on the bumper skin bracket, and others.

Price list.
3500 pound Badland winch from Harbor frieght on sale for $100, was $200
40" of 5x2 x .120 hot rolled rectagle tubing,
and 4' of 3/16 by 5" flat bar $45?
Grade 8 hardware $40...ouch.

and then there are added costs for cut off wheels, self tapping screws, and drill bits.




You will need to slit up the pinch weld in order to slide your brackets through, I went ahead and welded the gap against the body shut.


Secret hole in wheel well that is covered with foil. skimmed it out to 5/8th and sent a bolt through it.

I still have more bolt points to drill into these mounts

Notched to clear the blinker housings.





You will need to remove these lugs along the top of the bumper filler.


Do not eat













Over all it seems really strong and I can not wait to get stuck.

[TURTCEL]

Looks like you did an awesome job man. I have seen a couple other custom winch bumpers built for these cars but your set up seems the best so far. You didn't seem to have missed any reinforcing points either.

Keep us posted on it's use so we can see how the mounts hold up under stress.

Peace

[marlinh]

Nicely done!

[KZ750]

Thanks alot guys. This is one of the main things that i need to do still.

This bracket will utilize the stock mounting points on the uni-body rail with a 2" piece of angle iron, that corners up against the wheel well area, and allows me to tie my bracket into.

[dlb]

that's excellent. great photos. i'm sure this thread will be used as a guide for future peeps looking to do similar stuff.

[Tercel__jon]

I wish I had your patience and materials. This is going to be alot stronger than mine. (that I have to re-do to make it a proper winch bumper)

[KZ750]

Here's the finished product!

I welded on six tabs to secure the bumper skin two, and then made the two 90 degree brackets

[Gottolovem]

A man with skills and a welder impressive.

[larry mcgrath]

Nice job Larry.

[dlb]

any chance you could weigh all the pieces? just curious.

what are the six L-shaped tabs along the top rear corner of the bumper for?

[Petros]

that is a nice set-up. It should not affect the fuel economy at all, unlike the large pot rack type of front steel grill. I have been contemplating how a tube front grill would look like that would protect the hood and head lights from brush and particularly deer strikes, that would not affect the fuel economy. Use tear drop or elliptical cross section tubing perhaps, and keep all hardware minimal to reduce air drag. And incorporate a light winch perhaps. If it can be done lighter than that massive federal bumper, out of alloy, so much the better.

[KZ750]

dlb- It's actually not that heavy, which was on of my concerns. It's a little heavier than the stock bumper, plus the weight of the winch. Next time I have it off, i'll be sure to check the weight.
Petros- I'm way with you on that. Big bumpers are are just too impractical.
tear drop formed tubing sounds pretty costly! I would like to incorporate your idea of a hoop to protect the winch and the car from dear strikes.

[Petros]

areo tubing would only need to be the top hoop, and perhaps a couple of uprights.

like this:



from: http://www.aircraftspruce.com/catalog/m ... amline.php

might be able to find something like that surplus. I have a number of aluminum extrusions in this shape that were very expensive from official suppler, but got as scrap metal.