[redhatman]

Finally decided to tackle a big project to put my skills to the test, along with my welding/grinding/fabricating skills.

I will be making a Front winch Bumper for my ZJ, over the next...while. I guess when ever I get time. Spring break will provide lots of opportunities, which is next week. I just ordered my Winch from www.WinchDepot.com and should recieve that next week probably monday. $299.95 shipped, however they have it listed for $284.95 shipped so I will see if I can get that price instead. For some reason it goes to 299 when you add to cart. Winch is pictured without the control box.

Smittybilt Winches - XRC8 Winch

* XRC8 Winch
* Line Pull: 8000 lbs.
* Voltage: 12V
* Motor: 4.1 hp
* Remote Control: 12 Ft. Lead
* Gear Ratio: 265:1
* Size: 21 in. x 6.22 in. x 7.28 in.
* Weight: 80 lbs.
* Wire rope: 92 Ft. of 5/16
* Fairlead Roller
* Type of Winch: Electric

"The new Smittybilt XRC-8 Winch encompassses all the best features you would want in a winch. Every XRC-8 (8000 lb) winch features a 4.1HP Permanent Magentic Motor and a Planetary Gear Sytem with 265:1 gear ratio that will deliver you power and reliability without hitting your pocket book."



Anyway, for those of you with ZJ's know there arent many options out there besides CRB (not winch version), and Kevins Offroad (Very nice, yet run about $850 shipped). And, the recently discontinued Hanson Offroad Bumper line. Since this is not a TJ, you have to find your own mounting points. I have chose the framerails. I will grind out the frame rails to acieve the flat part (will see picture).





One I finish Grinding that out I will use 3" x 2" x 1/4" Angle Mild Steel in there. 2" being width, 3 inches being height. The gap when fully cut is 5" x 2". I will then take my nuts that match up with the threads of some grade 8 bolts, and weld them to the angle steel in the correct places. This way I can tighten the bolt without screwing around with a wrench too.

The Angle Mounts will stick out probably a foot or two from the flush part of the bumper fascia, and here is where I will mount my winch. I will have a plate of steel the length of the gap, and probably about 7 inches wide, 1/4" thick. I will weld this fully to the angle iron with some angle left still. gussets and all types of supports will be put into action. For added security, I will drill 2 holes on each side, 4 total through the winch mounting plate and through the angle iron on the top, but to the left and right sides. I will put grade 8 bolts in here, with nuts on the other side. This ensures that if the welds fails for some reason the bolts should catch it. I will also weld a fair lead mount on the front face of the mounting plate. The entire mounting system will be 1/4" Steel.

From here, I have yet to decide what to do. I figure if I make the rest of the bumper with 1/4" steel it will be heavier than the Jeep itself (not really, but darn heavy) and I would rather have the stress go to the mounts when pulling, not just from every day driving. So I was thinking 1/8" for the rest of the bumper? I already have tow points in the front, so I do not need D-Ring mounts. The rest of the bumper would just be for show anyway, with some possible mounts for my Hellas.

Thanks for reading. All input appreciated greatly. I am only 16, not an engineer so dont completely cuss me out lol.

Let me know what you think
-Pat

[TJ-Marine PA]

It sounds like it should work keep us posted.

[redhatman]

Originally Posted by TJ-Marine PA

I wouldn't weld the fairlead to the bumper face as they need to be replaced on occasion as the rollers wear, and cutting welds to replace a "minor" part is never fun.

I thought fairleads mounted with 2 bolts?

[PBR]

they do mount with 2 bolts

[aircruiser]

so youve actually got it ordered now?

this will be cool man

[rustywrangler]

I like how you thought to open up that front crossmember. Gonna follow this thread, father-in-law is gonna want a bumper at some point.

[redhatman]

Originally Posted by aircruiser

so youve actually got it ordered now?

this will be cool man

Yup, ordered and already shipped on its way to me. It will be cool for sure!

rustywrangler, hopefully I will do a good enough writeup for people to follow. I hate writeups with no detail. I will take pics as I go.

As of now, I really cannot decide whether or not to mount the winch plate on the brackets and then the rest of the bumper separate, or to have brackets, with a bumper separate as one piece and then have the winch plate on there.

Both have advantages/disadvantages. With the winch on the mounting plate, I will trust it a ton more. However, the bumper would be harder to mount steadily onto the brackets to a point where its fairly easy to remove.

With the winchplate on the bumper itself, it would be easy to mount and such, however I would need to make the entire bumper 1/4" to prevent bending.

With the winch on brackets I would do all the mounting 1/4" and then the rest of the bumper 1/8" being it is just for show anyway.

What do you guys think? Any Ideas?

[aircruiser]

just for show? wtf pat, you know youre gonna want to ram ****!

having a steel bumper just for show kind of defeats the purpose..id say winch and bumper seperate to give a stronger, sturdier support that is more reliable...but hey, thats just me

[redhatman]

Originally Posted by aircruiser

just for show? wtf pat, you know youre gonna want to ram ****!

having a steel bumper just for show kind of defeats the purpose..id say winch and bumper seperate to give a stronger, sturdier support that is more reliable...but hey, thats just me

Grant, 1/8" is plenty to ram things...especially those that roll on 4 casters and weigh around 40 lbs aimlessly in parking lots.

I am leaning towards the winch/bracket setup very much, its more of just finding a way to mount the rest of the bumper too.

By just for show, I meant that I will not be welding D-Ring mounts to it being I already have Kevins Front Tow Pointz. There will be no major force applied to it.

[aircruiser]

i guess i was thinking that you would weld on d-ring tabs...never mind then

[USMCredneck]

Originally Posted by redhatman

As of now, I really cannot decide whether or not to mount the winch plate on the brackets and then the rest of the bumper separate, or to have brackets, with a bumper separate as one piece and then have the winch plate on there.


What do you guys think? Any Ideas?

When I built the bumper on my old ranger I used 3x1.5x1/4 c-channel and just made a "subframe" type deal under the 1/8" diamond plate. Is it possible to do something like this on yours or would that be more trouble than its worth?

[redhatman]

I am not sure what you mean by that USMC, Basically from this pic:



You can see that there is room in there, however those bolts that are in there do have to go back in. I know for sure the right side wall nut plate is removable, and I would assume the bottom one is aswell. These were involved in the Radiator Supports/Tow Pointz. I really would love to run some 2"x4" in there, but I do not know how to get the bolts and nuts to line up without lots of hassle.

That is why I was thinking of :



I would trim to accommodate that angle steel there. The 2 nut plates, technically pull at the same time being there is an L bracket for the radiator support hugging the rail (90 degrees) that bolts into all 4 bolts. So I should be safe in just mounting to the 2 bolts in both sides right? (Other side is identical)

Other than that, I don't know what to do.

???

[redhatman]

Well, I just thought of something a lot better. It's 12:35 AM and this bumper thing is driving me nuts, I just want to get a solid plan so I am ready to work thursday when I have the day off (ironically enough) I get a day off, and spend the whole day working on other things lol.

So basically, assuming when I take out the 4 bolts per channel both plates can be moved, I will just make something like this:



That way, there is plenty of support when pulling from all angles, and I use a total of 8 bolts in the rails alone...All Grade 8.

My steel supply does not show a 2x4 channel, only 2 x 4 x 1/4" rectangle tubes. I would do that, but how am I supposed to get the nuts inside there?

[redhatman]

UPDATE:

Got to work on it tonight, I will get more steel tomorrow for the winch plate and a start on the bumper part. Mounts are done, I went with the 4 side ones which should be plenty. These are also tied to the lower 2 via the KOR Radiator Support/Tow Pointz.

Bottom Nut Plate that came factory was welded in, so I had to think of a new plan (opposed to the angle steel in the rails) Its all 1/4" Steel Plate, all Grade 8 hardware, cut to fit, nuts welded to stay in place. I will have to drill out more holes tomorrow when I get the rest of my material. Winch also comes tomorrow. Seems to be a strong mounting point, I am sandwiching the frame at every screw so it should help that way also.

At least I can stand on it and it doesnt break! LOL i hope it doesnt.

Onto the pics:

[BESRK]

Are you going to weld the nuts on a little more? Those tacks might break loose leaving the nut to spin inside the frame. Looks pretty good so far. From the first few pics, I thought you were only going to use 1 bolt in the side of your plate.. but the last pic showing the 4 bolts per plate looks pretty good.