I'm building a front winch bumper - TTORA Forum
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post #1 of 92 (permalink) Old 11-06-2008, 04:32 PM Thread Starter
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I'm building a front winch bumper

After wheeling this weekend and hitting my stock bumper AGAIN I decided to finally use some parts that I've had in my garage for a while. So I started to build a new front bumper. It is based around a TG 2nd gen winch mount. After doing some cutting on the stock mounts, completely welding where the factory didn't feel that it was necessary to weld and gusset the mount I could then start the bumper. It will be bolted to the stock mount with 4- 1/2" bolts and and 2 additional 1/2" bolts dropped thru the mount and the frame.




This will definitely help my approach angle. I now have 47*. The main bumper will be 2x2 square tube and have round hood/light protection.

*** No, the frame mount is not complete and does get more done to it***

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post #2 of 92 (permalink) Old 11-06-2008, 06:15 PM
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Quote:
Originally Posted by Gerdo View Post
This will definitely help my approach angle. I now have 47*.
How did you measure?

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post #3 of 92 (permalink) Old 11-06-2008, 07:50 PM
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I like the idea of having the hitch receiver in there.

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Donahoe's, 63'' Chevy's, ARB bumper, 255/75R16 Maxxis Big Horns, + other junk like my epic rear bumper build... LOL .
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post #4 of 92 (permalink) Old 11-07-2008, 08:36 AM Thread Starter
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Quote:
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How did you measure?
I took a long straight edge, sheet of plywood works great. I shoved it up to the tire and took my digital level and measured it.

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post #5 of 92 (permalink) Old 11-09-2008, 11:38 PM
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Good start. I will be looking at a front bumper among other things after last week in moab.




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post #6 of 92 (permalink) Old 11-10-2008, 02:21 PM Thread Starter
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I did a little work today. I figured since wood is quicker an easier to work with I would go that way. A couple of clamps and some tape and I'm on my way.


Just kidding. I made a quick wood one to get the shape, position and a template. I will be leaving about 3/4" between the bumper and the body.

Do you think this will be enough space for frame flex?

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post #7 of 92 (permalink) Old 11-10-2008, 03:47 PM
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I think 3/4" will be good. I started with 20mm (.79") on mine, and it's moved a bit over time, but never flexed up into the body.

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post #8 of 92 (permalink) Old 11-11-2008, 09:13 PM
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Just from an aesthetic standpoint I would bring the front of your tubing to almost flush with the front of your winch... it will eat up some of the gap on the top...

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post #9 of 92 (permalink) Old 11-12-2008, 07:56 AM Thread Starter
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It is tucked back as far as it can go. It's almost touching the winch. It can't go over the winch because then it'll be too high. It sits out about as far as the stock bumper, minus the "fat lip". I'm going to do my hood/grill protection hoops like the Shrockworks bumpers are, a slight lean toward the hood. This will visualy draw it back in. I'll also have some lights mounted over the winch filling the space.

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post #10 of 92 (permalink) Old 11-12-2008, 07:08 PM Thread Starter
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I got alot done today, the main bumper and all of it's supports. I also have most of the winshield washer bottle skid done. I need to get my lights back on and then the protection hoops.

It looks better in steel.



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post #11 of 92 (permalink) Old 11-12-2008, 08:02 PM
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Looking good so far. The little extra past the flair might get too close to the tire?
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post #12 of 92 (permalink) Old 11-13-2008, 01:23 PM
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I see a lot of room behind the winch that you could have tucked it more...


Don't get me wrong it's coming together. I would have just used plate in the front and tied the square tube in on either side of the winch...

I have a similar gap on the front of my truck and I prefer it to be covered or tucked. MrDoug's Badlands bumper is a good example.

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post #13 of 92 (permalink) Old 11-13-2008, 02:17 PM
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That 2" square tube looks a little familiar

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post #14 of 92 (permalink) Old 11-13-2008, 02:57 PM
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Quote:
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MrDoug's Bentup bumper is a good example.
Actually my front is a Badlands bumper, I think that's what you're referring to.

Tucking that winch up close is important tho... I bashed my fairlead a few times in moab last week.

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post #15 of 92 (permalink) Old 11-13-2008, 03:09 PM
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Quote:
Originally Posted by mrdoug View Post
Actually my front is a Badlands bumper, I think that's what you're referring to.

Tucking that winch up close is important tho... I bashed my fairlead a few times in moab last week.

Yeah but the rock gave... ok, Badlands it is... either way it makes sense to cover the top.

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post #16 of 92 (permalink) Old 11-13-2008, 04:32 PM
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Hmmm.....

Now you've got me wanting to start piecing together/fabbing up a front bumper for my truck!

Looks good, are you planning to plate it to clean up some of the gaps and such?
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post #17 of 92 (permalink) Old 11-13-2008, 06:03 PM
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Has me thinking the same thing. Your progress looks great! Keep the updates coming.




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post #18 of 92 (permalink) Old 11-14-2008, 09:27 AM Thread Starter
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I finished the main bumper yesterday and got a quick coat of paint on in the wind. Not the best finish but enough to protect it for now. Next I need to wire up the winch, get and mount a fairlead, spool on my rope. My family has a trip to MOAB planed for Thanksgiving. If I have time I'll be adding the protection hoops.

The ends of the bumper by the wheel wells are in the same place that the stock bumper was. I don't think the tire will be hitting it.



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post #19 of 92 (permalink) Old 11-14-2008, 09:35 AM Thread Starter
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That 2" square tube looks a little familiar
If it worked for you then it should work for me.

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post #20 of 92 (permalink) Old 11-14-2008, 12:08 PM
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Are you looking for a hawse or roller fairlead?

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post #21 of 92 (permalink) Old 11-14-2008, 01:30 PM Thread Starter
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Are you looking for a hawse or roller fairlead?
Aluminum Hawse. I'll be using 3/8" Tech-12.

I already have 2-rollers and 2-100' lengths of 5/16" wire cable that I don't need and want to sell.

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post #22 of 92 (permalink) Old 11-14-2008, 02:18 PM
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Congrat's.. looks good.

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post #23 of 92 (permalink) Old 11-14-2008, 03:43 PM
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Yeah it does, want to help me build one?




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post #24 of 92 (permalink) Old 11-14-2008, 04:14 PM Thread Starter
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Thanks. I could help you build one but I have to finish mine, finish my rear bumper, build some carts for work and I'm sure thereis more to do. I could help you.

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post #25 of 92 (permalink) Old 11-14-2008, 04:55 PM
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Cool, i may be giving you a call then. I plan on starting the layout for mine this weekend. The first thing i will have to figure out is mounting. Mine will be lower profile though as i think i am going to pass on the winch mount and just put a 2X2 reciever in it.




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post #26 of 92 (permalink) Old 11-14-2008, 05:46 PM Thread Starter
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Since I had the winch mount and most of a winch I had to go that way.

Building a mock-up from wood worked great. I just had to rember that I was building with 2x2 and 2x2 wood is only 1.5x1.5. Not a bug deal but had to rember what side to measure from the mock-up to steel. It was good to keep hacking away at wood to get the right lengths and angles.

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post #27 of 92 (permalink) Old 11-14-2008, 08:40 PM
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You might want to consider some hoops around the Hellas:

http://www.youtube.com/watch?v=bGt2ZwFZKPU
about 1:44 in ...

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post #28 of 92 (permalink) Old 11-14-2008, 11:30 PM
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You did a great job with your bumper. i just picked up on this thread, so if anyone is following along and liking what was done here I have a few ideas to toss about and get you thinking...
I got friendly with a local shop (read as "spend money there"), and the guy let me use his tubing bender. A case of beer or green in his pocket would do the trick too.. then I would take the long pieces home and cope them to my liking -
But FIRST - I reinforced the snot out of the stock frame horns - I felt those were too spindly for the torque and leverage that it would see.
To start the bumper, I welded the end of a short piece of tube closed, drilled a hole in the center and then bolted it to the front of the frame horn. That gave me a 3" tube sticking straight forward from which I could build.
I left the winch off, and just put in a reciever so I could put the winch on the back, on another truck, wherever.
In order to get the maximum possible approach angle, and keep the reciever as low and back as possible (to decrease leverage) I made the front tube center section removable to clearance the winch when it is mounted.
To keep the Aux lights as far back and protected as possible, I cut some vertical slats out of the grille (three per side) and set the lights flush to the front of the grill - even my deep, ballast integrated HIDs fit there cleanly.
Looks like you were able to keep the radiator skid, but since I went with a SAS, my radiator was very vulnerable so I had to make an extention for a skid - the local shop also has dimple dies, and I have a press, so.....the skid got swiss cheese'd and dimpled, and mike's pocket got $10 fatter.
Some mounting tabs and aluminum panels will hide all the ugly back there and offer better air flow around the bumper as well.
I also think that headlight hoops and a stinger of sorts is a good idea - seeing as how we live where the deer and the elk-a-lope play. I made the hieght of mine just enough so that I could see the top of the tube from the drivers seat. This I find handy for tight manuvers, yet does not encroach upon visiblity.

Anyway, there's my 2 cents - hope someone finds it helpful.

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post #29 of 92 (permalink) Old 11-15-2008, 09:01 AM Thread Starter
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Quote:
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You might want to consider some hoops around the Hellas:

http://www.youtube.com/watch?v=bGt2ZwFZKPU
about 1:44 in ...
Troy
They are set back pretty far but I have been thinking of how to protect them without obscuring them. Maybe do a Lexan panel. I wanted to keep them low because they are foglights and they hide alot of stock sheet metal.

It's also good to see Ron on the trail. Hopefully you'll get things straight and get back on the trail.

Packrat
Do you have any pictures of your build. I'm not sure if I can integrate any of your designs into mine at this point but I would like to see what you did. My plans do include some grill/light hoops.

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post #30 of 92 (permalink) Old 11-15-2008, 09:10 AM
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I really like where they are, and if I hadn't bashed in a light in pretty much the same place, I would say it's fine... but I bent the crap out of a 3/16 mounting plate for the turn signal - a glass lensed Hella would be toast.

Even a piece of rod (like rebar, maybe) bent to connect the angled pieces and loop around in front of the bottom of the light would do the trick I think.

Lexan, etc is just gonna get scratched and look like ass after the first trip down a dirt road ...

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