Well finally started chopping some big bits of metal for my winch mount. After much deliberation I decided to do it in 2 stages: stage 1 was the winch mount build where hopefully I will have the winch installed with the original bumper remaining, then stage 2 will be making a steel bumper to surround the winch mount.
I decided to do it in 2 parts because I need the Jeep for work so can't afford to have it in pieces while I fab up a bumper.
The winch;
I didn't want a bulky winch sitting on top of a plate 12" in front of the jeep reducing my approach angles and acting like a plough. So I cut away the front crossmember and mounted the winch back in tight to the radiator. The winch plate also sits in line with the frame rails so should reduce stress on the monocoque frame and the winch then should'nt hinder airflow to the radiator.
Materials used were 100x50x6mm section, 60x40x3mm section and 6mm plate. First I widened the frame rail entries and chiseled off the front welded nut that are used for the radiator support.
The 100x50 section was then cut to suit and pushed into the rail, the steering box limits how far the section can go in on the drivers side and was a real PITA to try and cut to shape. Four holes were drilled in each section to line up with existing bolt holes on the frame and nuts welded inside the section. The upper bolt hole sat too near the top of the box section so I threaded the section instead for that one.
I used 6mm plate cut and bent to shape for the winch plate and then 60x40 section was welded below across the winch bolt holes for added resistance to twisting.
The front crossmember was then cut out and the frame brackets bolted up in place. The winch plate was then slotted in place and tack welded. Then the whole bracket removed and welded fully and painted. I painted it grey to blend with the bumper and winch so it is discreet. (I'll need to find a better shade of grey!!!)
Next I cut the plastic bumper to allow it to clip back in place around the winch mount and trimmed the front grille to suit and finally wired the winch up. I'm fairly pleased with everything so far and the winch only sits 1" further out than the original bumper.
Hopefully the second stage of fabbing up some bumperettes should be a lot more straightforward.
Edit: By mod. made your pics bigger.
