Tubular winch bumper, home build.

[makeitfit]

Started to think about a winch bumper for the trol at the weekend and was suitably horrified at how much it would cost
So I'll make my own, again, how hard can it be ?
Sketched a few ideas on the back of a bill

Then got some measurements off the old girl's undercarriage

I just want it to be as strong as possible and also not too bulky. I will land on it, shift trees with it and generally abuse it
So back to the garage to cut up some ply as a mock up and got this far.

Box bit will be trimmed down lots yet. The tube bits are cut at the angle I want to protect the front of the wing. It'll be supported from below and behind to get plenty of fixing points and therefore strength

Plastic pipe here but will be straight, honest. Handy holes in the chassis for fixing points.

Base for the winch tray is to be 5mm steel and being bent now in the black smiths The tube part will also be 60mm and 3mm wall .
I'll put some update shots tomorrow

[NissanGQ4.2]

Good luck with the built mate, just remember lotsa pics

Just moved your thread into the DIY Bar Work section of the forum

Cheers

Todd

[threedogs]

Try to think triangle all the time, this style bar is popular here on Comp 4x4's.
May I suggest you make the winch section seperate from the side wings.
If you go as hard as you say hitting trees etc, the outer wings bend very easy.
make it so they bolt on, your 4by will never looked trashed, maybe laser cut
some plate and make a jig for the wings, so they're all the same. Use thick
walled steam pipe if availabe.

Wouldn't waste my money on seamless pipe.

[makeitfit]

Top idea, thanks for the advice.I'll weld up a plate on the end of the tube part me thinks

[threedogs]

Yeah its hard to make the wings really sturdy, thats the tri angle theme. while you have it off make a plate to slide up the inside of chassis with nuts welded on to pick up the three holes on passenger side so you can fit a recovery plate see my vendor thread. or some M40 eye bolts as front recovery point, eye bolts would be more versitile, bigger the better but pricey. keep us updated. theres a small slide plate for the trailing arms as well, but talk about that later eh

[makeitfit]

Got a bit further today with the winch tray part. All folded as I wanted it so time for some welding and trimming
Dry fit ready for trimming

You can see here roughly how far out it'll be , didn't want to reduce my approach angle any

Decided to put an extra fillet in for a bit more strength and help support the bolt on tube bits to come.

All was going so well and then the bloody welder packed up arse..............

So I'll have to investigate the welder's innards tomorrow damn it.............................

[threedogs]

Where it bolts to the chassis rail are you beefing up your winch box, also need decent plate up inside chassis?.
Down under we make them from 10mm, 12mm plate. are you fitting a low or high mount.
Looks great by the way, just not what I see here thats all, It all depends how strong this "BOX" is bolted
between the chassis. what style of welder is it ,ARC, MIG,??? coming along nicely Bud, keep the pics coming
only zinc coated, grade 8 bolts too

Drain holes ????? or slots make it lighter as well

Looks like a bit of rust on the chassis that requires attention too, or just mud?

[makeitfit]

Yeh cheers for that. Low mount winch, only a 12,000 lb jobbie, not winch challenge stylee lol I'm making an other piece of steel box to fit inside the chassis rails with welded on nuts. So there'll be 6 big ass bolts holding the tray bit on, same as the old pig tail ones. The box bit in the chassis will have the recovery swivels mounted in them and then bolted on the outside of the chassis too. The under side of the tray will be cut some more for drainage.
Chassis rails are a bit surface rusty and on the ever increasing list of to doooos :/
Mig welder.
My last winch bumper was 6mm and seemed to do ok but will look at some more strengthning on your advice, ta.
I'm using stainless bolts.

[threedogs]

Alls Good , for the drain holes. mark out a pattern with dividers centre punch drill then countersink a touch.
Looks more than strong enough all gunna be how this "box" is mounted, she''ll be right

[makeitfit]

Alls Good , for the drain holes. mark out a pattern with dividers centre punch drill then countersink a touch.
Looks more than strong enough all gunna be how this "box" is mounted, she''ll be right

You're obviously the man in the know on this stuff
I want to fit these swivel recovery points into the chassis ends, what are your suggestions ? Polite please lol
http://www.ebay.co.uk/itm/Recovery-s...item4a9ff5e3cf
Cheers Pete