Winch bumper

Winch bumper fabrication

Google Sketch-up design
Google Sketch-up drawing (download here)
Bumper design made in AutoCAD (download here)

The build

Got the metal cut at the dimensions and angles the way i wanted, just had to weld it together
First part done, i wanted to check the angle of the end pieces when the bumper is on the car
I clamped the bumper to some box section, the box section is the same as i used on the body-lift so it's between the body mounts on the chassis and the body
After a few tag welds i took the bumper of the car for some proper welding
Bumper back on the car, supported by a piece of wood which rests on a jack to support the weight
Test fit, winch and push-bar
Made a bracket out of cardboard
And this is the metal version, it's 6mm thick, a few tag welds will keep it in place until i take the bumper of the car again
The end piece clamped in to position to see how everything lines up
Under the new wider fender flares
Decided to change the shape a bit
Looks less massive in this way, and the only purpose of this piece is to protect the fender flare
Since i'm building a decent bumper i might as well make some solid recovery points out of 12mm steel
Clamped in position
Tag welds and test fit of the shackle
Welding and grinding done
Both sides done, now you don't have to reach down in to the mud looking for the stock recovery point
Winch-plate design made in AutoCAD (download here)
The Winch, Champion TDS-9500
Recieved the metal for the winch-plate today, it was bend just the way i wanted it.
Drilled the holes for the M10 bolts to install the winch
Opening for the fairlead, for the hawse and roller version, i will be using the wire-rope first, but after it wear's out i will buy some dynema
Welding the sides to the winch-plate
Winch-plate placed on bumper
Test fit, just to see how it looks
I'm not happy with the height of the push-bar which will be bolted to the winch-place, it should be a little lower
The winch-plate will be lowered 45mm
45mm removed of the bracket, the winch-plate will rest on the bracket to (will also be welded to it)
"Cut out" to place the winch-plate in
That's better
An other view
Done some welding and grinding, time for a beer
Made a brace on the bracket, so the winch doesn't bend the bracket when winching side ways
Took the bumper of the car for some easy acces while welding and drilled some holes to drain the water from the winch-plate
An other brace on the bracket for added strength
More welding done on the bench
Added a piece of angle iron for extra strength on the rear bolts of the winch (torsion of the winch drum under heavy loads can bend metal)
Time for some paint
Checking al dimensions
Installed the fairlead, and the wires for the turn signal lights, winch ready to drop in the tray
Winch installed and wired
Push-bar installed
Some extra lights installed
Cutting and measuring cardboard, to be used as template for checkerplate
Template check
Template done
Cut the 3mm checkerplate acording to the template and it fits great
Checkerplate installed with 6mm countersunk hexbolts
Radiator protection plate also made of 3mm checkerplate
Bumper done, and tested


Upgraded winch wiring from 25mm² to 35mm²
After extreme winching i lost all onboard power in the car, the alternator wanted to charge the battery with a high current which blew the "fuseable link" a piece of wire which act's like a fuse, but who has a spare for that in his car ?
I replace the "fuseable link" with some 6mm² wire and added a 40amp Maxi-fuse, also disconnected the charge wire from the alternator from the stock wiring loom and replace it with a 16mm² wire with a 80amp Maxi-fuse direct from the alternator the the battery