This is true, just use all grade 8 hardware and you are fine since thats sheer or around 150,000 psi, d1 bumper uses 4 at 1/2 diameter more then sufficient for a bumper and winch on this size vehicle

we did not weld mine to the frame or at least not on purpose cause i have seen to may frames tear or crack right at a weld, welding on a frame can be a great repair or great for adding strength if you know how to do it right without inatvertantly ruining or annealing the steel making it brittle

had i known i could easily fit a cheap jeep bumper i may not have built mine, which has no crush cans, a ranger backed into my front bumper last week his truck was the crush can

i would have made nicer mounts but other then ugly those will probly suffice as long as theres good penetration

 

Not if they are angle iron (I can't tell for sure if they are or aren't). Anything much beyond a straight pull (or push) will bend them. Angle iron has very little torsional strength.

 

like i said i would have made nicer mounts ....... were it a winch bumper i would be alot more concerned, though i also agree that side force pulling may not agree with that as pictured, this is why i boxed mine and slid it over the frame

irregardless of how its mounted what gets me how well a cheap jeep bumper works with a rover and how cheap they are compared to rover bumpers

 

The advantage of higher production numbers.

 

Since you brought up YouTube, here ya go!
My point is before you go using angle iron to mount your bumper you should probably educate yourself on the potential forces it will see. Recovery isn't a game, people get hurt or killed all the time. How would you feel if your half assed mount job hurt someone?
In a recovery situation I always inspect people's vehicles before attempting anything. Sorry, but I'd leave you stuck with that setup.

What do I do? I've worked in the Utility Dept of public works for the last 14 years. Today we cut in a 12" watermain valve and installed it in a 72" concrete vault. So if youre implying I'm just some keyboard jockey, I'm not. And yes I have a welder and am welding stuff on my project '95 D1. 1.5" x .25 wall DOM steering rods and 2.0" x .25" wall DOM jointed trailing arms with custom mounts welded to the frame, and replaced my stock diff covers with 3/8" thick sewer caps.
Tell me again about all the "cool sh*t" you build out of angle iron because so far I'm not impressed.

 

Oh cool, you pulled up a video of people setting up a bungee cord to fail, and then it fails, who would have guessed that outcome. Lets not use real situations to base requirements on. O.k. Mr public works guy, tell me how many lbs. angle iron will hold before it fails. I'ts obvious the frame will rip apart before welds or bolts would fail, we're past that.

No I wasn't trying to say you are a desk jockey. I was trying to say you probably work for the department of public works and have no clue what you are talking about, and should stick to cutting concrete and installing water valves instead of telling people who have been fabricating and building stuff their whole lives what they should and shouldn't do on their own 300 dollar truck.

 

Do yourself a favor and read up on Kinetic Ropes. They are extremely popular and effective and yes, act pretty much like a bungee cord. The demonstration was performed by vehicle recovery experts to show what happens when sh*tty equipment(your angle iron) fails.
I'm not a structural engineer and I'm guessing you aren't either since you wrench on cars(not that there's anything wrong with that). But you're going to sit there and tell me your angle iron will hold up better than the boxed truck frame when put under a side load? Ok, if you say so.

I don't care what you do on your $300 truck. But when you do something that is subpar and could possibly hurt or kill someone I'm definitely going to say something. Do the people you care about a favor and run back to Home Depot and buy 4 more feet of 3/16 angle iron and weld them in a box around your frame and back to your bumper.

Every so often a guy(like you) will come along and pound their chest(****) about the awesome stuff they build. And then they post pictures.......
The last guy I remember was RobertMirwin. I tried to link to the thread but the threads are closed or the links dead. Anyway, here's the awesome bumper he was building and going to sell. I know you weren't going to sell your bumper but the quality is right up there.

 

I'm not the dude you were asking, but I believe you can get them on Ebay for a pretty good price. I know I had one saved for a while that was priced at about $270-$300. Then about a month or two later, I checked it again and the price had shot up to around $650-$700. That was after the link got shared on this forum and people started buying them to mount to their D2's. I deleted the link after the price doubled.

 

Oh, by the way... this is what crush cans are used for... This happened to me last night at 7:30... lady ran a red light trying to "shoot the gap" in traffic and I smacked her doing about 30-35 mph.

 

So I was right, it is angle iron. The the mounting is even worse that I originally thought.
The weight doesn't have a lot to do with it. Very lightweight angle iron can handle a lot of stress in a well engineered assembly designed for the types of expected stress.
Those mounts are not well engineered for the stresses a bumper can encounter.

It's also obvious you don't really understand, or are intentionally ignoring, how the dynamic stresses in a recovery work.
In a kinetic recovery not only is the recovery vehicle applying force, but the strap or rope itself, by design, is applying tremendous force by it's elasticity to extract the stuck vehicle. If the strap can apply enough force to a 4,000lb truck to get it unstuck, it's not going to have much trouble moving a bumper weighing a couple hundred pounds.