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Unread 07-23-2014, 02:53 PM   #1
bonbon
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questions on my First bumper build

in my fab class at welding school, we have to choose a project to blueprint out and estimate cost and weld, etc. so ive decided that the time has come to replace that stock bumper.
im basically looking for tips/tricks/any input for a beginner. for material, thinking maybe 3/16 thick steel plate and MIG welding.

i do plan on (one day) adding a winch to the set up. i dont have one yet to measure off of though.
my idea is to have the winch set low and inside, behind the front plate of the bumper for protection, with a fairlead on the front. question is, exactly how much room do i need for a winch? i'll drill mounting holes later, i just need a basic length/width to leave a space. another question- fairleads. are most the same size with the same hole spacing? im thinking of using one of those billet aluminum ones for the synthetic line. there would be a small piece sticking up from the front place for a fairlead.

other ideas are holes for lights and some loops on the front for d ring shackles.

ill post a rough sketch of the design when i have one drawn up. sometime this week i have to measure out and make a cardboard mock up to see how the thing would even look

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Unread 07-23-2014, 05:58 PM   #2
youngjeepr
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I don't know the measurements for a winch off the top of my head but if no one else can tell you I'll go measure mine.

If you plan to run a winch I would build the winch mount out of 1/4".

I like to TIG all the stuff I fab just because there is less grinding to make it look good. Or I can stack small and tight dimes for a certain look or if I want the bigger look I'll use a mig.

What type of jeep is this going on?
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Unread 07-24-2014, 06:36 PM   #3
RM77CJ5
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Patiently waiting!
I'm planning on the same thing for the wife's Jeep. Neighbor made his own of of round pipe. Looked real nice. Simple!
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Unread 07-25-2014, 03:30 PM   #4
bonbon
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Going on an 01 tj.. the stock bumper must go!
1/4 mounting plate Wont be a problem at all. If you could, I'd appreciate some measurements just to have a ballpark range.

RM I should have a rough sketch up soon, I like the tube look on jeeps for sure. Is that what thr wife will be getting?
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Unread 07-25-2014, 03:37 PM   #5
youngjeepr
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Quote:
Originally Posted by bonbon
Going on an 01 tj.. the stock bumper must go! 1/4 mounting plate Wont be a problem at all. If you could, I'd appreciate some measurements just to have a ballpark range. RM I should have a rough sketch up soon, I like the tube look on jeeps for sure. Is that what thr wife will be getting?
I'll go measure my winch in a little bit.

If I were you I would buy a winch plate then build the bumper around that. That way you don't have to a bunch of drilling,measuring and bend it for the fairlead.
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Unread 07-25-2014, 03:40 PM   #6
youngjeepr
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Winch length-21.5"
Width-6.5"
Height-6.75"

Bolt pattern- 10"x 4.5"
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Unread 07-25-2014, 03:42 PM   #7
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And that's a warn m8000
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Unread 07-25-2014, 11:41 PM   #8
4xfiend
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Quote:
Originally Posted by bonbon View Post
i do plan on (one day) adding a winch to the set up. i dont have one yet to measure off of though.
my idea is to have the winch set low and inside, behind the front plate of the bumper for protection, with a fairlead on the front.
TJ's have a tube crossmember at the front of the frame. How exactly do you plan on recessing the winch? Cut out the crossmember? There is a reason you see very few TJ's with recessed winches and, instead, see them mounted on top of the frame.
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Unread 07-27-2014, 10:30 AM   #9
bonbon
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Quote:
Originally Posted by 4xfiend View Post
TJ's have a tube crossmember at the front of the frame. How exactly do you plan on recessing the winch? Cut out the crossmember? There is a reason you see very few TJ's with recessed winches and, instead, see them mounted on top of the frame.
Well, It just dawned on me last night that that isnt really possible.. for whatever reason it never clicked that the tube was in the way. quite the facepalm moment i must say haha.

what i think i will do instead, is have my mounting plate rest just above that tube and have a slightly taller front on the bumper where the fairlead will go, which will also offer some protection for a winch. at a later time i might work out a way to put a tube or bar over it, but for the sake of time on this one ill leave it out for now.

today i am working on a cardboard mock up, ill post some progress as it comes along.

youngjeepr thanks for the measurements, i do have a buddy that might have an old winch plate laying around if he hasnt used it.
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Unread 07-27-2014, 10:49 AM   #10
bonbon
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Here is a -very- rough sketch of the bumper and some of the pieces.
since i cant recess the winch because of the cross tube its just going to go about even with the top of the frame rails and the front will be slightly taller.
imag3193.jpg  
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Unread 07-27-2014, 02:13 PM   #11
youngjeepr
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Looks good.

If I remember right my winch plate was $40 or so but it was powder coated.
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Unread 07-27-2014, 09:38 PM   #12
140mower
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That is along the lines of what I did, I took the pieces I took out of the top and the ends and pieced them together on the bottom, which allowed me to move my bumper up in it's mounts a little. i made it out of some scrap I had lying around, now i'm working on a rear..........
pict0166.jpg

pict0110.jpg

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Unread 07-27-2014, 11:12 PM   #13
youngjeepr
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Here's the last one I built. The winch is just sitting on there in the pictures but I do t have any good ones with it mounted.



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Unread 07-29-2014, 05:28 PM   #14
RM77CJ5
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Quote:
Originally Posted by bonbon View Post
Going on an 01 tj.. the stock bumper must go!
1/4 mounting plate Wont be a problem at all. If you could, I'd appreciate some measurements just to have a ballpark range.

RM I should have a rough sketch up soon, I like the tube look on jeeps for sure. Is that what thr wife will be getting?
Who knows?
I just know she hates the look of the stock one on it now! This is only a weekend cruiser to the grocery store and maybe a trip to the riverbed or beach.
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Unread 07-31-2014, 07:33 AM   #15
bonbon
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Really nice looking bumpers guys! Ive got the cardboard more/less finished, still have to do the back and underside. If I can upload from my phone I'll throw up a pic shortly, otherwise later today!
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