Angry Monkey Winch Bumper BUILD

I started building a winch bumper a little while ago. I didnt think about starting to take pictures until after the winch basket was built, but Ill try to document the rest if anyone is interested. The which shelf, front face and supporting gussets are all 1/4 and the "skin" is 10 guage (a country hair over 1/8)

I definitely dont have a fully stocked shop. Everything is painfully cut with cutoffwheels and angle grinder. I dont have a drill press either, so all the holes are cut with a hand drill and alot of patience. 1/4 is difficult to work with without the proper equipment lol but very doable in your home garage.

Started with a the rough idea mocked up in cardboard


I had a machine shop bend the winch holder into shape since I most definitely dont have a 1/4 brake. I didnt take any more pics until I started cutting the fairlead holes. 2 1/4 holesaw vs 1/4 steel = much patience needed lol




Measuring and cutting other holes in front face




ANGRY MONKEY!!!




Starting on the skid


Welding the skid


Welding the top


This is as far as I have gotten now.... ill work on it some more tomorrow and update. Would love to hear your thoughts

 

Great looking welds. How much do you think you will have into it when you are done? (taking into account your own labor)

Matt

 

Looking good. Is the whole thing gonna be 1/4" plate? Are you gonna back gouge or just butt weld everything?

 

That's a happy bumper with headphones

 

Well unfortunately this is the stage where it will sit now for the next 2 weeka. I was hoping to have it done for a trip starting this weekend, but I got off to a late start. I will carry on in a couple weeks and finish off.

 

Ill probably have 300ish in materials including cutoff wheels, flap discs, holesaws, welding wire and metal. Labour is another story. Ill tell you one thing, when your getting a $1000 bumper, its really not as expensive as you would think. A production shop will have big shears and plasma cutters to help speed things up, but I am finding quickly that everything takes longer than you would think. I am fairly new to metal work though, im sure I will get faster.

With my time included, im sure it would have been cheaper to buy a production bumper, but I dont really count my time bcause it is a fun project for me, and I get a one off piece in the end.

 

Trip got delayed for a couple days. I wired my winch and relocated the solonoid under the hood. I have it mounted ontop of the fuse panel for now, until I have time to fabricate a braket. I can still open the fuse block if necessary.



Then I got out some cardboard and started mocking up the wings for the bumper



I took it apart and will cut out the other side and weld it tomorrow.

 

All cut ready to go


Tacked


Found this on my roof. Why do cats love cardboard so much?


Welding


After a loooooot of grinding, getting a degreaser bath in the sun




Some primer


Some bed liner


Winch installation


All done, minus the sides. Ill get to that when we get back from our trip. We are going 4x4 camping in the Caribou/Chilcotin in Bc.




Monkey Face, no longer evil! Lol. I think I'll call him George.


Yup after all that work my license plate is zap strapped on lol o literally ran out of time though, I worked until the minute. Ill mount it nicely in a couple weeks.

 

For someone "new to metal working" that's pretty damned impressive. Great work! I can't quite tell from the pictures; is there enough of a gap to allow for frame/body flex so the bumper doesn't contact the grill, fenders, or headlight bezel?

 

Ill definitely take that as a compliment. I only started welding 3 months ago, but practiced alot before start this project. This is, however, my firat really involved metal project I have tackled.

Its tough to tell from the pics, but the bumper sits infront of the headlights and grill. Frame torsion shouldnt be a problem until I put the fender sides on. Im thinking about 3/4 inch.

 

Got a little dirt on it

 

That looks pretty nice man! Were you planning on making some brackets to tie the bumper into the frame further back or is it just mounted with the six studs for the OEM bumper?

 

It is mounted to the 6 studs, plus 2 on the bottom of the cross member, plus tied back to the frame with a bracket I purchased from Relentless. It mounts by 10 attachment points.

 

Sounds pretty strong. I was thinking of those exact brackets. I got mine from bamf to use on my demello bumper.

 

Great job, looks awesome but i bet its heavy.

 

That looks absolutely incredible! You motivated me to learn how to use my Hobart Welder I got for Christmas!

 

Very impressive. Good work man

 

Good job, it looks strong and capable. I want to start welding myself and be able to eventually build similar projects.

 

Very nice work! You can be proud of your work, I never really count my own labor anyways as long as I'm working on my own rig.