Custom Bumper Fabrication - Mounting Question
 

I'm starting to work up some plans for a custom bumper to weld up and I'm wondering what the best way to mount the bumper to the frame would be (I'm, in the very beginning stages). Remove the crush cans and use:

A 2x4 square tube (3/16th thick) mounted inside the frame rail with 3 grade 8 bolts per side?

Or outside the frame rails with a bracket left and right of the rails with 3 grade 8 bolts per side?

I've been reading a bunch of build threads and have seen it done both ways.

I plan on putting a winch between the frame rails, so strength and rigidity will be important.

What do you guys think?

Send me your e-mail address and I'll send you pictures of what I did and I doubt you will find anything stronger.

i will post up some pics of mine after work today, should be easy to see, i took my bumper off last night. bent plate strap to sandwich the outsides and used original holes.

recently, modeled these after the mounts, that i received with a previous disco bumper. original set up called for that angled inside support, have a 1.5 hole drilled in the bottom, for nut access. this time , I enlarged the holes and welded fixed nuts in. my winch is in bumper, though. I like the ease of loosening, but not removing the bolts, to lift off the bumper.

Thanks guys, I think I'll go with the outside!

Hello,
I just joined the group and have a 2002 Discovery and looking to build a front bumper using my Fabrication Shop. Can you please send me any build information on the same to mohd.yasir.kv@gmail.com