winch bumper progress

[malcolmzilla]

A few pics, kinda makin it up as I go...

What is everyone doing to affix them to the frame? I was thinking about filling the factory holes and sleeving the inserts and bolting all the way thru, so I get both shear and compression of the frame on the inserts...

 

[SC74]

Very nice fab work. I also like the idea of sleeving the mounts. I would beef up the tab between the hole and end of frame rail too - seen those rip out before.

 

[malcolmzilla]

Thanks, getting used to using the torch.

For affixing it, I'm thinking of using 7/16" bolts all the way through, both horizontally, drill through below body mount and filling the factory bumper tabs and drilling another bolt vertically thru there but a bit farther back...

Mine has been front ended so I had to heat and beat and weld the frame horns and slots back into shape, so drilling a bit farther back out of the HAZ is advisable I think...

 

[malcolmzilla]

Todays progress...

 

[brian72]

oh good - more photos, cause I thought it was going to be one small bumper...

 

[hammer]

Thanks for the pics. I'm going to have to tackle this as well. Really helps wrap my head around it.

 

[MustangHowie]

It is looking good. I can't wait to see it complete, and on the truck.

I plan on taking mine to work this spring and making one for mine.

 

[trlblazr]

I like how that is looking. I too will have to fab somthing soon.

 

[JHD]

Very nice keep the pics comming

 

[Devin]

That is looking really good. Thanks for posting the progress.

 

[Fugly]

Looks great! I like it!

 

[drscotch]

Nice work! ;D

Is that 2x4 HSS you're using to slip into the frame? What wall thinkness is the HSS?

Thanks,

 

[malcolmzilla]

2x4 .120 wall inserts, same wall as frame. Takes a bit of hammering but goes in and out.

Bumper and winch plate is .188, cut out of 2x8.

Progress so far today. Let me know which side line you like: 18", 19" or 20". ;D

 

[BG's 68 Bronco]

I'm thinking 18"

 

[dieselracer]

Yeah, 18" with a piece of 1/4" plate that caps off the bumper and protects the fender back to the edge of the flare. That looks awesome. Eventually I will get around to building one. I have been contemplating a pre-runner style with two tubes that will go around the top front corners of the fenders/grill and tying them into the main hoop too.

 

[drscotch]

I'd go 18, I'd hate to run my knee or thigh into 20 walking around the front. ;D

Do you know if that 2x4 0.120 fits the rear frame as well?

Thanks

 

[malcolmzilla]

I dunno about 18", might not keep much off the body... thinkin' 19". 20" is a bit wide.

 

[malcolmzilla]

Split the difference @ 18.5"?

I will post the rear inserts when I get back to working on the rear. Yes they fit, with a bit of notching for the bodymounts.

Just out and picked up some towhooks, had a factory forged set off a K3500 but they are too big and ugly. They will be hidden underneath out of sight.

Plan to add a strongback to rear of the winch plate, this will also give me a spot to pound the sledge on to remove it - I am mushrooming the rear lip right now - the last 1" takes persuasion.

Also got the back horizontal bolt holes drilled using the factory one on the inside as a pilot, had to trim the drivers body mount back a bit, should take 1/2" bolts.

I am also debating doing a hidden mount for the front vertical bolts...

Also, I dont think the winch will come out without removing the bumper, ~1/2" to grille... Hopefully slow a thief down. And a tackweld on the footbolts.

Debatin' hilift mounts too. Can do 'em later, kinda diggin the flush look.

I'll snap some more pics as I go.

 

[DonsBolt]

Looks like your doing a awesome job

I say 18 at the most, but I like things Tight, hehe

Something like I did when I modified my B built Bumper ends

 

[malcolmzilla]

More pics, with winch in, the angle iron represents the grille location when mounted. Big assed tow hooks: free, you pay shipping! ;D