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Unread 02-05-2010, 10:26 AM   #1
YJhobby
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Lowered (between the rails) winch bumper design/build

Okay guys, I've been designing a front bumper for my YJ that positions the winch plate on the bottom of the frame rails, allowing the winch to sit between the rails. I am looking for design flaws or oversights from those of you who know more about retrofitting my whole front end with a custom bumper/crossmember.

My reasons for designing such a bumper are listed below:

-I wanted a challenge, and a unique look for my Jeep
-Lower CG (not much but I'm using it as a reason anyways)
-Aesthetics (I like the look of Hanson and ARB bumpers, but not the price)
-Protection for my winch
-Ability to customize the end caps for long or stubby setup (also good for damage repair)

Please take a look at my first thread about doing this in the YJ section for more background info: http://www.jeepforum.com/forum/f12/t...bumper-931159/ You will notice several changes from that thread to what I am planning here, and I am pretty sure it will change slightly again due to your input.


I plan to start with the standard YJ front end with a 3" diameter tube front crossmember and weld my 1/4" thick 7" wide winch plate to the bottom of the frame before I cut out the crossmember. See the next few pictures:

stock-frame.jpg   winch-plate-assembly.jpg   winch-plate-attach.jpg  
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[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



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Unread 02-05-2010, 10:31 AM   #2
Ironworker709
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Won't the steering box be in the way of the winch in that area?
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Unread 02-05-2010, 10:33 AM   #3
YJhobby
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Next I plan to remove the crossmember and cap the inside portion of the "thru-hole" to make a solid frame to weld to on the inside. Next I plan to add a set of shackle attach points to the bottom of the new winch plate for my leafs to attach to. Then I can add the front plate to form the "front bumper" portion.
tube-removal.jpg   shackle-attach.jpg   front-fairlead-attach.jpg  
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[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



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Unread 02-05-2010, 10:35 AM   #4
YJhobby
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Quote:
Originally Posted by Ironworker709 View Post
Won't the steering box be in the way of the winch in that area?
Hmmm... not sure, but sounds like it would. I guess I might have a steering box relocation or project modification in my future. Thanks for the heads up and I'll look into this further once the rain lets up
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[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



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Unread 02-05-2010, 10:43 AM   #5
YJhobby
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Next I was planning on adding shackle mounts welded to the inside of the frame where the tube used to be. The finishing aesthetics for the bumper is the slanted bottom plate that shouldn't negatively effect the approach angle or swinging of the shackle on flex.
add-shackle-hangers.jpg   add-lower-fairing.jpg   bumper-base.jpg  
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[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



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Unread 02-05-2010, 10:53 AM   #6
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I like it so far. But you should enclose around the frame to fill the empty space. And maybe give it some shorty endcaps.
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Unread 02-05-2010, 11:06 AM   #7
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Quote:
Originally Posted by RitterXJ View Post
I like it so far. But you should enclose around the frame to fill the empty space. And maybe give it some shorty endcaps.
The plan is to make some bolt on endcaps to complete it... I think a set of shorty endcaps with steep upward angles about 5" long, and a set of longer endcaps for DD protection and when I am just out and about. I figure about (4-5) 1/2" bolts with guide sleeves welded through the frame will hold the end caps securely enough to survive an impact or two before replacement
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[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



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Unread 02-05-2010, 11:38 AM   #8
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i love it!!!! how about using some big angle? cant wait to see it finished.
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Unread 02-05-2010, 12:35 PM   #9
RitterXJ
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I think you should weld the nuts for the bolts onto the frame bumper for much easier removal and installation.
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Unread 02-05-2010, 03:59 PM   #10
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Wow, I love where this is going!
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Unread 02-05-2010, 04:15 PM   #11
YJhobby
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If you check out the link to my other thread you can see the end caps I have planned for it... Since I only have access to CATIA at work I'll have to wait till Monday to add the endcaps with thu-bolts

It does look like the steering box will take require some modifications to the drivers side of my winch plate, but I guess some big gussets should maintain strength
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[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



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Unread 02-05-2010, 04:28 PM   #12
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Quote:
Originally Posted by Ironworker709 View Post
Won't the steering box be in the way of the winch in that area?
Yes, it will.

I did something similar on my YJ (but with less plate and more tube), and the mounting structure was far back enough that it would be totally where my steering box would have been (I didn't use a mechanical steering box). I was running a narrowed comp-style winch too. My friend Rob did the same thing with a Warn 9000 not narrowed and there was only a couple of inches between the frame and winch on either side.

Here is my old Jeep.


I ended up cutting the frame off in front of the engine mounts and tubing it for lower ride height and improved suspension travel. You can see how I made the winch mount in this picture. A piece of 1.5x.120 across the frame rails with a piece of .25 plate flush with the bottom of the frame, connecting the 1.5 tube to the bumper. The piece of tube was right behind the steering box sleeves so there wouldn't have been any room for a box if I ran one.

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Unread 02-05-2010, 07:53 PM   #13
wozz
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Is that Catia I see there. Cool I idea!
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Unread 02-11-2010, 10:41 PM   #14
509media
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Very Cool. I built a similar set up on my YJ about 12 years ago. You will have to work about the steering box but it is not a big deal. You can find pics of my old red Jeep HERE I did not narrow the winch to make it work if you are wondering.

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Unread 02-12-2010, 02:42 PM   #15
John_Wayne
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Thats a really cool idea. I might do that this summer...
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