My front winch bumper build thread(update 5/18, not done, but installed)

[DonsBolt]

Yo guys
I started the build of my bumper last night, so I decided to start a new thread to document the build.

Picked up some steel yeasterday
2 peices of 2x8 3/16th
2 peices of 2x5 3/16th

Last night I made the first two cuts from the 2x8 tubbing
I read a few other bumper build threads, and they all used 2x6 tubbing, by going with 2x8 I was able to cut the back side of what will be the side peices, instead of the front like I saw in the other threads. I like this option, as the welding will be on the back side of the bumper, giving the front edge a cleaner look with less grinding after welding.

Here are some pics, the first 2 pics the plan of the bumper, 3rd pic laying out the template, 4th pic, clampping metal to help get straight cuts, last two pics, side peices cut. By going with 2x8 peices, I have two extra peices of metal I can use for bracing of the ends

Will post more pics as I make more progress, and assemble the bumper

 

[Justafordguy]

Lookin good so far. What are you cutting it with?

 

[sprdv1]

Look forward to it Don! good luck

 

[DonsBolt]

Lookin good so far. What are you cutting it with?

hehe for the end peices, I just used my 4.5 inch grinder, will use it for the frame peices too. Though for the center peices, I am going to have a metal shop cut and bend those.

 

[Justafordguy]

I just used my 4.5 inch grinder

I bet that wasn't fun. LOL

 

[needabronco]

My 4.5" grinder cuts like butter! It just burns through cutting disks.... The hardest part for me is getting a 'scribe' in first that is straight, after that it just burns through.

Your bumper is looking great.

 

[DonaldDouchebag]

Nice work, sir!

 

[DonsBolt]

OK pics number 2
did a rough cut on the frame rail peices, and cut two little wedges out some of the extra material

Just for the hell of it I tuened the frame rail peices upside down, put the end peice, and a wedge , and took two pics

First pic, frame rail peices
pics 2 and 3 the frame rail, end peice, and wedge sitting upside down

 

[73EB]

Looking good. So, how much will you have in materials?

 

[DonsBolt]

right now $85 bucks what you see in the pics. Not sure what the other metal shop will charge me for the winch mount, and the center plate

I also orderd 25 grade 8 flange nuts and bolts from McMaster-Carr
$11.41 for the bolts
$8.65 for the nuts

Really only need 12 or so, but since I will have 25 I may bolt the end peices to the center before I weld it all together, so even if the welds brake, the bolts will hold it together

Edit I looked at my recept from the steel place, it was $60 not $85 like I thought, even better

 

[piack]

Hey Don, looking good. What happened to the old one? I thought you had a Baily Built.

 

[DonsBolt]

Hey Don, looking good. What happened to the old one? I thought you had a Baily Built.

Yes it was a Bailey Bilt bumper, and I sold it to ken
It was a great bumper, but wanted something that sits a little lower

 

[DonsBolt]

anyone have a good recomendation on a good shackle mount, or D ring??

 

[Justafordguy]

I know you can buy the shackle mounts off of Ebay but I cut mine out of 3/4" x 1.5" bar stock. Drilling the 7/8" holes was kinda tricky.

 

[Apogee]

Though not particularly cheap, Ballistic has some nice shackle mounts that may or may not work well with your bumper design: http://www.ballisticfabrication.com/Tabs_c_231.html

Poly Perf has something similar here: http://www.polyperformance.com/shop/Poly-Performance-Weld-On-Clevis-Mount-p-24739.html

I prefer shackles, but there's something to be said about captured D-rings that can't be stolen. If you do use a weld-on D-ring, make sure it's forged and properly rated for it's capacity. Here's a link to one I was considering for a project a while back.

 

[DonsBolt]

The Ballistic ones are nice, but a few inches to short
Looks like I will make my own, unless someone has a better option

 

[ken75ranger]

A few friends of mine used these guys for bumper parts.
Trout Industries
Good parts and they are in Pa so shipping is a little cheaper.

 

[Wyflyer]

I know you can buy the shackle mounts off of Ebay but I cut mine out of 3/4" x 1.5" bar stock. Drilling the 7/8" holes was kinda tricky.

They have some at Harbor Freight for about 5 bucks each.

 

[Steve83]

These can be found in your local junkyards, or e-mail me.

. . . . .

 

[DonaldDouchebag]

Though not particularly cheap, Ballistic has some nice shackle mounts that may or may not work well with your bumper design: http://www.ballisticfabrication.com/Tabs_c_231.html

Poly Perf has something similar here: http://www.polyperformance.com/shop/Poly-Performance-Weld-On-Clevis-Mount-p-24739.html

I prefer shackles, but there's something to be said about captured D-rings that can't be stolen. If you do use a weld-on D-ring, make sure it's forged and properly rated for it's capacity. Here's a link to one I was considering for a project a while back.

What's your opinion on the d-rings and brackets off a Hummer H2?