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My very first winch bumper build

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Old 06-04-2017, 12:32 AM   #1
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Default 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.
My very first winch bumper build-resized_20170221_175552.jpg

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

My very first winch bumper build-received_10213409791058067.jpg

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

My very first winch bumper build-resized_20170529_220213.jpg

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

My very first winch bumper build-resized_20170603_193402.jpg

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.

My very first winch bumper build-resized_20170603_232541.jpg
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Old 06-04-2017, 02:47 AM   #2
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Looking good. I guess the final product depends on your welding skills
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Old 06-04-2017, 10:17 PM   #3
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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.

My very first winch bumper build-resized_20170604_181902.jpg

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.

My very first winch bumper build-resized_20170604_170235.jpg

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

My very first winch bumper build-resized_20170604_194153.jpg

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.

My very first winch bumper build-resized_20170604_212801.jpg

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.

My very first winch bumper build-resized_20170604_215821.jpg

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.

My very first winch bumper build-resized_20170604_221151.jpg
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Old 06-07-2017, 10:18 PM   #4
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More progress
driver lower qtr, end caps and then some filler on the "deck" of the bumper.

My very first winch bumper build-resized_20170607_194101.jpg

My very first winch bumper build-resized_20170607_205459.jpg

My very first winch bumper build-resized_20170607_214229.jpg

And then some test fitting of the winch and fairlead

My very first winch bumper build-resized_20170607_215547.jpg

My very first winch bumper build-resized_20170607_215603.jpg

My very first winch bumper build-resized_20170607_215646.jpg

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!
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Old 06-08-2017, 03:55 AM   #5
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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.
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Old 06-08-2017, 08:50 PM   #6
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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!
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Old 06-13-2017, 09:49 PM   #7
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Started out tonight by drilling out the clevis mounts. brand new 1" drill bit and the milwaukee had a dance, and it was Hot!
My very first winch bumper build-resized_20170613_191903.jpg

My very first winch bumper build-resized_20170613_194406.jpg

matched the tab and made a duplicate from 1/4" plate
My very first winch bumper build-resized_20170613_203944.jpg

My very first winch bumper build-resized_20170613_204206.jpg

All welded up and blended in
My very first winch bumper build-resized_20170613_215122.jpg
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Old 06-14-2017, 12:49 PM   #8
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looking good, what are you planning to paint it with?
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Old 06-15-2017, 09:02 PM   #9
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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
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Old 06-17-2017, 08:26 PM   #10
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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!

My very first winch bumper build-resized_20170617_204340.jpg

My very first winch bumper build-resized_20170617_204355.jpg
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Old 06-20-2017, 09:01 PM   #11
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Awesome
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Old 07-09-2017, 05:57 PM   #12
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Over this weekend i wrapped things up on the bumper. Got into my buddy's shop and bent some tube up.

My very first winch bumper build-19894922_10213843078409980_4133860244073005616_n.jpg

My very first winch bumper build-19884050_10213843078769989_5158011468931367501_n.jpg

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.

My very first winch bumper build-resized_20170708_121206.jpg

My very first winch bumper build-resized_20170708_121223.jpg
Some fresh welds

More bedliner and mounted. Tossed a 12k badlands winch in there.
My very first winch bumper build-resized_20170709_182119.jpg

My very first winch bumper build-resized_20170709_182127.jpg

My very first winch bumper build-resized_20170709_182139.jpg
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