My Winch Bumper Project

[Mountain Goat]

Not sure if this is the right spot for a build log, mods feel free to move this if necessary. I'm taking a welding fabrication class this semester and plan to build a winch bumper. Please let me know what you think of my design. There are a few details to be finalized such as the contour where the bumper meets the truck, but the significant dimensions are correct. My plan is to build it all out of 1/8" steel to save weight, with the exception of the winch mount which will be made of 1/4" plate. I purchased a winch which should be here Tuesday, so I'm pretty committed to the project. It will take me a while for sure because I only have the class once a week, but I will post progress here as I go.

[atancreti]

What about protection encase you hit a dear or something? Maybe weld some steel bars that go up in front of the bumper? Just for the headlights and grill.

[Mountain Goat]

Originally Posted by atancreti

What about protection encase you hit a dear or something? Maybe weld some steel bars that go up in front of the bumper? Just for the headlights and grill.

I agree. It all depends how much time I have left in the semester after I finish the main bumper, but I'd love to do a "roo bar" as the Aussies call it. I was talking to my wife and we agreed if I did hit a deer with this rig it would probably go right under the tires, not up and over. LOL.

[JoeManly]

It looks like the back side is open from the center to the edges, I think you will need to add a few stiffeners between the top and bottom plate or it will tend to twist and warp while welding. It looks like you are boxing in the sides, that's probably overkill just add a few vertical plates between the top and bottom to stiffen it up. The front plate in the middle where you are mounting your winch could use a small lip across the top, maybe another 1" plate or whatever fits to make the cross section a "C" shape instead of "L" shape. 1/8" plate is very light so it will warp very quickly if you don't jump around spread the heat over many different areas, I would recommend you tack the whole thing up with very small tacks, test fit, then weld it out very slowly, never putting more than a few inches at a time before moving as far away as possible to another spot to let the original spot cool. Good luck

[Mountain Goat]

Originally Posted by JoeManly

It looks like the back side is open from the center to the edges, I think you will need to add a few stiffeners between the top and bottom plate or it will tend to twist and warp while welding. It looks like you are boxing in the sides, that's probably overkill just add a few vertical plates between the top and bottom to stiffen it up. The front plate in the middle where you are mounting your winch could use a small lip across the top, maybe another 1" plate or whatever fits to make the cross section a "C" shape instead of "L" shape. 1/8" plate is very light so it will warp very quickly if you don't jump around spread the heat over many different areas, I would recommend you tack the whole thing up with very small tacks, test fit, then weld it out very slowly, never putting more than a few inches at a time before moving as far away as possible to another spot to let the original spot cool. Good luck

I may add a lip to the front if I can still fit the winch in there. The other option I've considered is have the center section protrude up slightly more than the rest, and have rounded corners, but I don't want to block too much airflow to the grille. That part is 1/4" plate so I'm not too worried about it bending. I will definitely add some web stiffeners on the back like you mentioned.

As for my welding plans, I'm going to build just the winch plate first which will look like this:



The winch mounts on the Z-shaped piece which is all bent from a single 1/4" piece. There will be a hole in the front for the fairlead.

All the other pieces I'm planning to cut, bend, and tack in place like you stated, and then test-fit the bumper. In fact I bought a protective welding blanket that I can drape over the hood and grille so I may tack it together with the winch plate already mounted, so I will see instantly if everything is fitting properly. For welding all the seams I was already planning to stitch-weld, just 1 or 2" at a time then move on.

Thanks for the input.

[JoeManly]

I misunderstood where you were mounting the winch,(top not front) you'll be fine with no lip. I was stressing the heat warping the metal because I made a rear bumper a few years ago out of 1/4" diamond plate left over from a job and got impatient welding it out. It warped the tiniest bit but it I noticed it every time I got in the truck for the 5 years I owned it. Funny how little things will sometimes bother you. Post some pics when you get it done I would like to see how it turns out.

[Mountain Goat]

Yes I will post pictures as I go and also when I'm done. I intend to make it as good as commercially available bumpers, but with a better approach angle than most.

[HLC Fab]

You're design looks good and shouldn't cause any issues with covering the grill. Rovers aren't affected by having the radiator partially covered as bad as other trucks. I would recommend using at least 3/16" plate instead of 1/8" for added strength and to counter the warpage that you'll encounter. The frame brackets should also be left open on the top and bottom for adjustment up and down and to allow them to get tight enough to limit the bumper from pivoting. Keeping it boxed might prevent the clamping force you need.

[Mountain Goat]

I've thought about 3/16" plate but I really don't want to make it too heavy. I mean I bought synthetic winch line to save me 20 pounds on the nose, I'd hate to burn that all up with extra steel. I guess I'll calculate the weight difference before I buy parts. And yes, good point about leaving the top and bottom of the mounting brackets open, I noticed that on the OEM bumper and wasn't sure if that was necessary.

I have about two weeks to sort out the final design before I get to start on this so it's a work in progress. I'm pretty sure this shape will work though and look good as well.

[Mountain Goat]

Santa Claus arrived today with a very large, heavy box!