i am in the process of building a rear bumoer and tire carrier. The bumper is made of 6x3x3/16 and the carrier is 2x2x3/16. In the past i have snapped the bumper bolts out of stock location. I am thinking of running a 2x2x3/16 in unibody rail and mount that using hitch locations. I am also thinking of enlarging the mounting flange on the bumper legs and instead of using stock bolt locations, going a little wider., drilling new holes and then sandwiching the back metal lip inbetween the bumper flange and a piece of 1/3 by 3inch wide steel for every two bolts. So 4 in total for 8 bolts. Do you think this will hold up better than drilling out the stock bolt location and reusing that?

 

I hear what your saying about the bigger plate... great idea, the bigger "footprint" will spread the stress out and make it stronger, as long as you don't go too much bigger, then you'll need more bolts thru it. AND yes go in to the unibody with the 2x2 and bolt in from bottom

 

X2. Just got my rear bumper with tire carrier finished.And tied into the hitch locations on the factory strip nut.A wider foot print is a great idea on the stock upper location.