DIY Winch Mount/Bumper

[pocketlock]

Interested in building my own winch mount that can eventually become a bumper. I bought some 2x4-3/16" wall tubing to slide into the front and rear frame horns. How deep should I focus on getting it inside the frame? I was planning on at least 3 bolts per horn minimum. More if I can find the space. I was planning to use a HF winch mount and either weld or bolt it to the 2x4 that will stick out of the frame and trim off the excess. About 7-1/2" deep for the winch mount. So how much engagement should I be looking for on the frame side? I was planning to trim down the rivets slightly for the body mount to get it in as deep as possible. Planning to use the slotted oval holes in the frame as solid bolt points, plus one on the inside of the frame and I may add another on the outside if there's room. Just looking for some suggestions. This will be a winch mount first and a bumper second but I want to be able to add some tubes on in the future to make it protect the whole front end. Thanks!

 

[Yeller]

As deep as possible, but if you can 3-4” past the notches on the side of the frame you’re good. If you through bolt the frame and tube be sure to weld in sleeves to keep it from collapsing. Using the original bumper bolt locations and 1 bolt in the side is plenty, no reason to do a 4th, especially if you’re using 7/16” or 1/2” bolts. Remember the winch is only held on with 4 - 3/8” bolts.

Don’t be afraid of using Riv Nuts to bolt it together. It’s easy to Make a Tool to set them. The other 2 options are to through drill and use a sleeve like you would for mounting a steering box or to weld a nut on the inside of the tube, but it’s very difficult to do when you can’t reach it with the welder.

 

[Broncobowsher]

As deep as possible.

I'll drill some 5/16" holes through both the frame and insert. Pull out the insert and tap the holes for 3/8 bolts. Drill out the frame for 3/8 bolts. I also take the aircraft approach and use a lot of small fasteners to spread the load. The frame isn't that thick and prefer to not put all the load on a few large bolts that could easily pull through the frame without even stressing them. Multiple small fasteners spread the junction all over. By drilling through both pieces at the same time means they will be aligned when removed and reinstalled later. The tapped wall of the insert is probably the weakest part, but quantity makes up for it.

 

[399strokerEB]

I made one a couple years ago to get me by. I'll try and get some pictures and measurements when I get home.

 

[pocketlock]

I made one a couple years ago to get me by. I'll try and get some pictures and measurements when I get home.

I would appreciate it! Thank you!

 

[399strokerEB]

 

[pocketlock]

Awesome! Thank you!

View attachment 899286 View attachment 899287

 

[pocketlock]

View attachment 899286 View attachment 899287

How do you access the nut to bolt this in? Seems like it's pretty far back, or do you have the tubing threaded? Debating if that's the best option for me, just thread the insert.

 

[399strokerEB]

I drilled through both sides of the frame and used a long bolt. I'd weld nuts to the inside next time.

 

[FordBronc]

I did that same thing on the front and back. The heavy duty square tubing was test fit first by putting it in as far as it would go. Wthout a sledge hammer. Then taken back out and welded to the bumpers. Then reinstalled and bolted thru the frame and welded to the end of the frame horns. Overkill yes, but solid as a rock.

Same for the front, the receiver hitch was already welded in the square tubing bumpers. I would of rather flushed it up with the bumper face to not have that part sticking out like a mini chicken beak. I would of had to reach behind the bumper to pin the winch or tow point, no big deal.

Last 3 pics are other ideas from folks on here.

 

[sprdv1]

As deep as possible, but if you can 3-4” past the notches on the side of the frame you’re good. If you through bolt the frame and tube be sure to weld in sleeves to keep it from collapsing. Using the original bumper bolt locations and 1 bolt in the side is plenty, no reason to do a 4th, especially if you’re using 7/16” or 1/2” bolts. Remember the winch is only held on with 4 - 3/8” bolts.

Don’t be afraid of using Riv Nuts to bolt it together. It’s easy to Make a Tool to set them. The other 2 options are to through drill and use a sleeve like you would for mounting a steering box or to weld a nut on the inside of the tube, but it’s very difficult to do when you can’t reach it with the welder.

As deep as possible.

I'll drill some 5/16" holes through both the frame and insert. Pull out the insert and tap the holes for 3/8 bolts. Drill out the frame for 3/8 bolts. I also take the aircraft approach and use a lot of small fasteners to spread the load. The frame isn't that thick and prefer to not put all the load on a few large bolts that could easily pull through the frame without even stressing them. Multiple small fasteners spread the junction all over. By drilling through both pieces at the same time means they will be aligned when removed and reinstalled later. The tapped wall of the insert is probably the weakest part, but quantity makes up for it.

Great advice and lots of knowledge/know how here

 

[pocketlock]

Made the frame inserts today. Bolted in with 4 9/16” bolts. Trying to decide wether to weld or bolt the winch plate on. Probably going to attempt to weld it to give me a place to put some hooks into the frame inserts for pulling.