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Unread 11-06-2011, 10:44 PM   #1
skyj
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YJ stubby winch bumper

Well it all started with a Craigslist ad for a Warn 5687. I have always wanted a old Warn winch on my jeep. I know its No 8274 but its close enough. I cut it all out of 1/4 steel, drilled some holes, and bent it at an angle and welded it to another piece of 1/4 steel then bolted it to my existing bumper anchor points. I know how much everybody loves pics so here they are:

It sat like this for a year or so and I finally got my butt into gear. I planned on capping off the front end with a angled piece of steel and adding some d ring mounts. then I stumbled upon another craigslist add for a beat used Smittybuilt rear tire carrier. It had the typical problem with the weight of the tire ripping off the welds for the spindle. I picked it up for $35.

I will be using the tire carrier part for my rear bumper build but with a quality spindle. will be starting that as soon as Im done with the front bumper.
So I took the lower portion of the bumper and cut it at 33" same width as the frame. then I cut the ends off

then I tacked them back on:

then I added D ring mounts:


this is pretty much where I am at as of today.

Its a slow build. I use my dinky crasftman 110v welder to tack it all together then I haul it over to my buddys house and I burn it all together with his welder. there is still lots left to do. I have to gusset the bottom and weld on tie in points to the frame. after looking at that last pic I think I need a new fairlead roller too. the hook and cable clamps are only temperary that is what was attached to the winch when I bought it. Like I said before its a slow build so it may take me awhile before Im completely done. and just for giggles heres the jeep its going on.



Last edited by skyj; 11-14-2011 at 01:11 PM..
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Unread 11-19-2011, 05:12 PM   #2
skyj
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Well I havent got much done on the bumper. Its been way to cold up here to do much on it. My garage is insulated and heated, but my buddies where I will be burning it all together isnt . I have been doing a lot of hunting lately too. I dont know about you guys but this has been the worst year for me hunting . It finally snowed here about 6 inches so we will see how the last week of the season goes. Then I will get back to welding this darn bumper.
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Unread 11-19-2011, 07:19 PM   #3
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Unread 11-21-2011, 10:56 AM   #4
hallway94yj
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It looks like you didn't drill your holes through your clevis mounts before you tacked them onto that bumper, if that's so, have fun drilling through that! Looks good though, I basically did the same with my smitty bumper
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Unread 11-21-2011, 01:43 PM   #5
skyj
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Quote:
Originally Posted by hallway94yj View Post
It looks like you didn't drill your holes through your clevis mounts before you tacked them onto that bumper, if that's so, have fun drilling through that! Looks good though, I basically did the same with my smitty bumper
Got any photo's?

I knew I forgot something...... Yeah!! I drilled a pilot hole I think it was 3/8.(the biggest I had). I didnt have a 7/8 drill bit at the time I did it. It is still just tacked together so I could just grind off real quick before final welding. I dont think it will be to difficult to finish drilling, just use 1/2, 5/8, 3/4, then 7/8's. Thanks for the tip
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Unread 11-21-2011, 01:59 PM   #6
shu2kill
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Quote:
Originally Posted by skyj View Post
Got any photo's?

I knew I forgot something...... Yeah!! I drilled a pilot hole I think it was 3/8.(the biggest I had). I didnt have a 7/8 drill bit at the time I did it. It is still just tacked together so I could just grind off real quick before final welding. I dont think it will be to difficult to finish drilling, just use 1/2, 5/8, 3/4, then 7/8's. Thanks for the tip
i think you would want to drill up to 1" for 3/4 shackles... the pin diameters is 7/8, so drilling at 7/8 would get a really tight fit, add mud and dirt, and you will have your shackles stuck there... JMO
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Unread 11-21-2011, 02:08 PM   #7
skyj
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Quote:
Originally Posted by shu2kill View Post
i think you would want to drill up to 1" for 3/4 shackles... the pin diameters is 7/8, so drilling at 7/8 would get a really tight fit, add mud and dirt, and you will have your shackles stuck there... JMO
I was going to drill them out to 1" but it seemed to big and sloppy and would rattle around. I might just file them to open the hole up a little bigger, or go with a 15/16 drill bit.
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Unread 11-21-2011, 03:07 PM   #8
hallway94yj
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Mine is on page 3 http://www.jeepforum.com/forum/f37/s...umper-1197634/
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Unread 11-21-2011, 03:15 PM   #9
skyj
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WOW! hope mine turns out as good as your's
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Unread 11-21-2011, 04:17 PM   #10
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i was going to post my thread but looks like HALLWAY beat me to it.

looks good SKYJ.

keep us updated
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Unread 11-21-2011, 08:14 PM   #11
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So what is everyones consensus on the size of hole that should be drilled 7/8, 15/16, or 1" ? I still think 1" is to big and it will rattle what say you Jeepforum?
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Unread 11-21-2011, 08:20 PM   #12
hallway94yj
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1". If your jeep is driven on the road like mine, I highly doubt that your jeep is quiet enough to notice that hahaha
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Unread 11-21-2011, 08:23 PM   #13
hallway94yj
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Here's a better picture of my front bumper...

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Unread 12-22-2011, 12:39 PM   #14
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Alright I got a little more done on the bumper, not much but something. I got a little pre-ocuppied with mounting my TJ flares . Well since hallway94yj was so worried about my clevis mount holes I figured I better get those drilled before I burned it all together. 15/16" hole saw Not bad for no Drill press HUH?



Hopefully on Friday I can head on over to my buddies Shop and get it all burned together and maybe after Christmas get it all mounted up on the Jeep.
Dont hold me to it though
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Unread 01-02-2012, 04:42 PM   #15
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Alright dont laugh too hard at my welds I fought my buddies welder the whole time so I ended up stacking my welds. I welded it with his Snap-on welder mig/tig.( yes I used gas. heat set at 8 and speed set at 3-4) He has had it for ten years and never learned how to use it so I gave it a try. Lets just say my welds looked crappy( way too much spatter.)

After welding with his welder I came home ground off the spatter then hit it with my 110v and stacked it on top making C's.

Im not too happy with the cosmetics of the weld, but hopefully with enough paint it will look a little better. I think I will try POR15 on this bumper. After this I have convinced my wife I need a good quality welder what do you guys suggest on a budget? I dont think I can afford a Miller unless its used.
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