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Unread 10-07-2013, 05:56 PM   #1
Dumpsterfish
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The dumpster bumper: the successmanship continues...

So, after the sliders, project 2 is a steel winch bumper. While I'm laying out my design, I have a question for the experts on this board:

I'm putting together this bumper using 1/4" hot roll plate. Assuming it's fully welded, do I need a separate winch plate tied in to my frame rails? I'm hoping I can just build a tray into the interior of the bumper.

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Unread 10-09-2013, 08:57 AM   #2
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I incorporated a separate winch plate into my stubby bumper, but I also only used 3/16 hot rolled, not 1/4". Most winch plates I've had my hands on were 1/4", so I think you are absolutely fine mounting directly to the bumper. If you are mounting your winch above the frame rails, I'd gusset the interior of the bumper beneath it, but that's probably overkill.

Throw up some pics of your project once you get going. We're all picture whores here.....
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Unread 10-11-2013, 02:09 PM   #3
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Build out: day 1

Had the day off yesterday, so I cruised the remnants section at IMS, and found some 1/4" A36 plate. Figured I'll just cut it up with the plasma and save a few bucks. Picked up some flat bar and 6" squares to round it out:



image-2758498079.jpg


Took some measurements with the stock bumper removed:



image-3855799959.jpg



image-1930268696.jpg

Got out the old plasma cutter, and made some parts. Then measured and drilled the holes where the front will mount to the frame.



image-521387664.jpg

Welded up a few parts:



image-484252591.jpg



All went well until fit up time. Turns out my plasma cutting skills leave a bit to be desired. So my welds suffered, and at the end of the day I ended up with this:



image-703801981.jpg
image-2944272863.jpg

image-907761712.jpg

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Unread 10-11-2013, 02:10 PM   #4
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Damn send button...ended up with this.



image-3489845169.jpg
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Unread 10-11-2013, 02:16 PM   #5
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Ok, so this morning I made coffe, sat down to post yesterday's progress, and ended up re-designing the whole thing.

After some more measurements, I worked up an end cap design out of cardboard and tossed it on the jeep to see how it looks:



image-4089234144.jpg

Likin'it! So I got out the old graph paper and pencils, racked my brain (math hard. Coffee good), and came up with a drawing/cut list.



image-3317672961.jpg

Lessons learned yesterday-the hassle of cutting this out of plate would be lessened by just buying a bunch of 6" flat bar. Only one piece is wider than 6", and I'm gonna see how much IMS will charge to chop me off a piece of place in that size, 7.625"

Will post up when I begin building v1.1. Now what to do with this 70 lb piece of scrap...
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Unread 10-11-2013, 02:29 PM   #6
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I wish I had metalwork skills.
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Unread 10-15-2013, 11:08 AM   #7
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In the end, you will wish you made the majority of that bumper with 3/16" plate instead of 1/4".
I built my stubby TJ bumper out of 1/4" and even being a small fraction of the size of yours, it weighed a ton. I am not one of those 'ditch all steel for aluminum' guys, but I know a cruise ship anchor when I see one....after building mine. By the time you finish that bumper and throw a winch in place, you will be in the neighborhood of having an extra 175# on your frontend. That is not something you will enjoy.

Using 1/4" plate for the winch mount is not a bad idea, but the surrounding steel only needs to be 3/16".


Anxious to see what you come up with, though!
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Unread 10-15-2013, 01:14 PM   #8
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Well timed post...I was just reconsidering the 1/4 yesterday. After doing the math, it looks like my design will weigh 86 lbs with all 1/4", 67 lbs in 3/16", and 80 lbs if I keep winch related pcs at 1/4" and move everything else down to 3/16".

Looking at JCR and Ace bumpers (3/16 and 1/4 respectively), I see they weigh in at 100 and 67 lbs (for a stubby with hoop). So I'm not far off the mark, at least.

If I break out the TIG welder and make the whole thing out of aluminum, it's a breezy 26 lbs in 1/4". Would still need a steel mounting plate though.

Looks like a lot of commercially available winch bumpers are in fact made entirely of 3/16. Would I be ok strength wise ditching the 1/4 entirely?
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Unread 10-15-2013, 02:45 PM   #9
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I ditched my homebuilt all 1/4" bumper for a Motobilt bumper of similar size, made entirely of 3/16"...including the top where the winch mounts. I am however also running their winch/fairlead mount that is another piece of 3/16", so I essentially have my winch mounted to doubled up 3/16" steel.

At worst, I would weld some flat bar ribs to the underside of the bumper to stiffen the winch area.
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Unread 10-15-2013, 03:57 PM   #10
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Hmm ok. Might as well give it a shot.
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Unread 10-15-2013, 11:21 PM   #11
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OP, I mentioned gussets in my earlier post, but didn't really indicate that I had used them with my stubby made entirely out of 3/16. I asked Eddie when I ordered my clevis tabs what he thought and he recommended surrounding the clevis tabs with gussets internally. I only used one clevis mount and placed a gusset on either side of it inside and then plug welded the gussets to the clevis tab as well as the interior of the bumper skin. I also added 2 additional gussets near the frame ends. You can see them here....



Like I said, I added a 1/4" winch plate to the top and married the whole thing together. It hasn't been tested hard yet, but it's not going anywhere. REALLY solid.

Here's a link to the build if you think it may be of any help or give some ideas...

http://www.jeepforum.com/forum/f37/y...build-1534995/
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Unread 10-15-2013, 11:30 PM   #12
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Quote:
Originally Posted by firefighter315
OP, I mentioned gussets in my earlier post, but didn't really indicate that I had used them with my stubby made entirely out of 3/16. I asked Eddie when I ordered my clevis tabs what he thought and he recommended surrounding the clevis tabs with gussets internally. I only used one clevis mount and placed a gusset on either side of it inside and then plug welded the gussets to the clevis tab as well as the interior of the bumper skin. I also added 2 additional gussets near the frame ends. You can see them here.... Like I said, I added a 1/4" winch plate to the top and married the whole thing together. It hasn't been tested hard yet, but it's not going anywhere. REALLY solid. Here's a link to the build if you think it may be of any help or give some ideas... http://www.jeepforum.com/forum/f37/y...build-1534995/
Thanks! Yes, gussets seem like a really good idea.
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Unread 10-23-2013, 11:57 PM   #13
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Ok, so good progress today. Got all my pcs cut and fit up...



image-4207620327.jpg



image-2638424227.jpg

Then I tacked everything up. Had to cut the last couple angles pcs by hand. Just marked out dimensions on plate and used a cutting disc.



image-1162728481.jpg



image-872225129.jpg



image-1200765513.jpg



image-215242374.jpg

Pretty happy with results so far. Will have to wait until Friday to test fit and start finish welding/grinding.

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Unread 10-24-2013, 08:31 AM   #14
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Looks good!
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Unread 11-09-2013, 11:46 AM   #15
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So I had a few hours yesterday, figured I'd get some work done. First I test fit the bumper on the frame mounts, only to find that my support ribs hit the lowest part of the frame, preventing the bumper from sitting flush. This is why we tack! Ground off the lower portion of the ribs:



image-1928820079.jpg

And Whaddya know...it fits! Woohoo!



image-1236783920.jpg



image-3062644113.jpg


Then it was on to the welding table, where I welded and ground the end caps:



image-3365541993.jpg



image-604139056.jpg

I saved the middle portion, as I want to cut out holes for my fog lights. After a trip over to the plasma cutting stands:



image-1335552189.jpg

Not bad for freehand! To make fog light mounts, I grabbed some scrap tubing (4"? Not sure) and miter cut about half of it to the same angle as the lower portion of the bumper:



image-1934479246.jpg

Then bent up a couple chunks of 16g pickle to make mounting tabs, and voila:



image-1516189577.jpg

Now for the crappy part. My plasma cuts left some pretty giant gaps. Between those and the different thicknesses of the bumper/fog mounts, had to get tricky with patching/welding:



image-2086018618.jpg



image-1036510938.jpg


That's as far as I got. Still have to finish welding the top and add the hoop, as well as clean up the fog light mounts a bit. May end up having to use a tiny bit of bondo (the horror!) to make everything look nice and smooth. Then it's rattle can time.

Hope to finish by next week. Then it's on to the next!

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