today i finally had time to begin with my front bumper. so far, i just made the shackle mounts and the plates that bolt to the frame. i had these cut in the local plasma cnc shop, thats why it is not exactly homemade.
i cut 2 of these, which bolt to the frame. i read in here that the holes were 3/4", but that was wrong. on my jeep (sahara 2008), the top outer holes only accept 1/2" bolts, but the other 3 holes accept 9/16". so thats what i did. unfortunately i had already cut the holes at 3/4" but thats OK since it gives some adjustment. the bolt are welded to the plate, since once finished, i wont be able to get a wrench in there.
sorry i didnt take pics of the actual plates, but thats the drawing i took to the shop, and the plates bolt right on. if i were to do it again i would change the size to 9/16 though....
then i had them cut 2 of these:
and 6 of the same one but only 3/4" long. all the plates are 1/4" thick, so stacking them i get a 1" shackle mount. the long one was welded to the side of the first plate, on the inside of the frame rails, and the other 3 were welded to the front part. i had to cut with the grinder to make some room for the bolts.
this is the only picture i have, ill take better ones tomorrow after i finish welding everything. after grinding it will look like a 1" thick plate. the rest of the bumper will be made out of 3/16" thick plate.
i will weld the winch plate between the 2 8" long plates, i havent determined the height yet, but most of the winch will be between the frame rails. i have a Warn M8000, so the control box is separated, i think ill put it centered, barely covering the grill.
i will add another plate on the front, with slots for the shackle mounts to go through. this way, they will be welded directly to the mounting plates, and to the front plate, instead of only welding to the front. i will be updating as i progress. with me working out of town from monday to saturday, i guess this is going to take a while....