My very first winch bumper build
 

So i've done plenty of welding projects but never a bumper. I'm also not one for critical measurements so this bumper will mostly be "a lick of the thumb and squint with one eye". The bumper is being setup as a reasonable clearance bumper. Nothing crazy but still plenty for protection. I don't really have any doodles or drawings of what its gonna look like. Just going with the flow using mostly leftover bits i have in the garage.
Attachment 301842

Starting out with a pair of 1/4 steel frame mounts. They are full length tie-ins with 6-bolts per side

Attachment 301844

Followed up with making the jeep level all around, Center of frame, center of the A-member and the same with the brackets.

Attachment 301843

Next came the winch plate, old and slightly rusty 1/4" plate. Oh and this 4 or so year old "brand new" end table that i've had sitting around. Rated for 12k, good ole Badlands winch Sarcasm

Attachment 301845

I had some pieces of 2x6" 3/16 wall with some angled cuts on them already, they fit pretty nicely on the sides of the frame mounts. Finished up the night with the fairlead mount and the face plates.

Attachment 301846

Looking good. I guess the final product depends on your welding skills

welding skills - Check

So as i had said before.... using leftover bits in the garage. Mostly sourcing all the 1/4" plate from this poor mans 5th wheel plate that came in the back of my J2000 project.

Attachment 301879

Jumped right back into this bumper and welded in the front plates and fairlead supports. I will add some gusseting behind these later in the build.

Attachment 301880

next came another chunk of 1/4" for the lower front portion of the bumper.

Attachment 301881

Finally chopped off the ends of the 2x6. They were both different cuts originally and Luckily there was just enough material for the driver side to still be symmetrical. These will still be capped off later in the build.

Attachment 301882

Another chunk of 1/4" makes up the lower bottom qtr's. This was a little tricky to get and i had to do some finesse grinding but it setup pretty nice in the end.

Attachment 301883

I don't believe i mentioned this before but my build will all be done with Flux core. I personally could weld with this All Day without issues. Not as clean as mig but its cheap and I'm no professional welder. So it gets the job done.

Attachment 301884

More progress
driver lower qtr, end caps and then some filler on the "deck" of the bumper.

Attachment 301980

Attachment 301981

Attachment 301982

And then some test fitting of the winch and fairlead

Attachment 301983

Attachment 301984

Attachment 301985

Still need to drill out the clevis mounts into the front, pull the bumper off and do some finish welds and add a couple gussets in some select spots. Then just Maybe some tube work!

Looks good, I am just getting started on my bumper build and in my head it is remarkably similar to yours, I've only got the mounting plates cut so far though.

That's awesome and it's definitely a start! I clicked through pages and pages of "custom" bumpers for the XJ's on google and really couldn't base it off any of them. I knew i wanted a mid depth mounted winch and also a practical bumper with a little style to it. Not just a piece of 2x4 or 2x6 slapped across my front end. Welded the winch plate and just kinda went from there with what i had in the garage.

Totaling up my $ invested so far into this, I'm still under $40. Thats $15 for the brackets i had custom cut out on my buddy's plasma table - $20 for a new spool of flux core wire and about ~$5 for the hardware to mount the bumper. I've gone through prolly 12 cut-off blades (which were free to me) so that has really saved me some cash!

If you haven't made a fab thread for yours yet then you prolly should! Share your creation, it could inspire other to build there own!:thumbup:

Started out tonight by drilling out the clevis mounts. brand new 1" drill bit and the milwaukee had a dance, and it was Hot!
Attachment 302129

Attachment 302130

matched the tab and made a duplicate from 1/4" plate
Attachment 302133

Attachment 302131

All welded up and blended in
Attachment 302132

looking good, what are you planning to paint it with?

More than likely just duplicolor bedliner. The hood has been done with it also the rockers, fender lips and rear bumper have been done with it. Simple cheap and it just plain works

So for now the bumper is set to go. dragged the jeep outside for some pictures and also a much needed wash and a quick blast of dublicolor bedliner.

The tube work is still in store no worries!

Attachment 302217

Attachment 302218

Awesome

Over this weekend i wrapped things up on the bumper. Got into my buddy's shop and bent some tube up.

Attachment 302822

Attachment 302823

Wasn't really much to it, the center hoop was just the two bends "matching" the angles of the winch mount plate. The two outer pieces of tube were just 90* bends. Just tacked on for the moment and then hauled it home for finish welds and paint.

Attachment 302824

Attachment 302825
Some fresh welds

More bedliner and mounted. Tossed a 12k badlands winch in there.
Attachment 302826

Attachment 302827

Attachment 302828