This is part 2 of our build up of a tube bumper and winch
In typical DIY fashion, I always start by laying out the parts in the location I would like to put them.
I say “would like” on the picture above because even though I usually go in with a plan, parts of it are almost always changing. I like to not make my build plans too rigid that way I can change and modify the design as the build progresses.
Once I decided for sure where I wanted the winch
I had an interesting issue with this build in that the clearance between the radiator/grill and winch
If I end up bending the fairlead someday, guess what? It’s only metal and at that time I can either fix it or build a new one that is even stronger.
Since I had cut off the front of each frame-rail I can’t just leave them like that. So it is time to cut out some gussets to reinforce the frame and receiver tubes
Two cardboard gusset templates cut out and in place.
I also mocked up two tubes to reinforce the ends of the bumper.
I like to show the picture above with the chain come-a-long hooked to the bumper to show that fabrication isn’t always sunshine and rainbows. This is DIY metal fabrication after all, and it requires ingenuity. The gap between the bumper and fender didn’t quite match from side to side, so I had to use the chainfall to pull the tube out just a bit until I could weld in the reinforcement.
I coped one side of the reinforcement tubes with my tubing notcher then cut the other end with the grinder. I have an emotional attachment to the scrap piece of tube in the picture because it at one time was a part of the front bumper on the CrAzYbLaZe.
Here you can see where the tube hits the frame. I cut the tube off little by little with the grinder until it fit right.
I laid the cardboard templates on a piece of 1/4″ steel then marked around them with soapstone. After that, I cut them out with my plasma cutter
Gussets in place ready to be welded. You can see I went ahead and drilled the holes for the winch
Gussets welded up.
Close up of how the gusset ties the winch
The gussets should really tie everything together and make it strong. Not to mention it cleans up the front end and makes it look a little bit more like a bumper.
Next, I had to find a spot to mount the solenoid pack to mount. I couldn’t leave it on top of the winch
It just so happens that the connector on the winch
Because I was remote mounting my winch
You can buy a premade winch solenoid extension kit
The extension kit is made from 2 gauge wire and these Dorman 85635
Here you can see the wires installed on the solenoid ready to install. There was also a small black controller ground wire that I had to extend.
As seen in the pic above there are 3 main power wires going from the solenoid to the winch and I didn’t want to get them mixed up. So I bought colored electrical tape
While installing the extension kit, I wanted to protect the wires where they contacted the frame. An old piece of radiator hose with a slit down the side worked great to contain and protect the wires. (not to mention it was free!!)
Painted the bumper. The black makes the winch
Bumper painted, winch
This is a side view so you can see why I worked so hard to recess the winch. The addition of the winch did not affect my approach angle at all.
Finally, a picture of the front bumper outside and offroad!!
More pics of it off-road here: KS Rocks Offroad Trip
This was a fun project, and it is one that you can do yourself at home with a welder, drill, grinder, and some motivation. It doesn’t have to have bent tubing in it. Simply adjust the design of the bumper to use the tools and abilities that you have. You can easily go out and spend $1,000+ on an aftermarket winch