Lifting lug recovery points

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Hi guys,Just after a little bit of advice, in regards to plating a bullbar, i think you guys call them brush bars, where i am getting some lifting lugs welded on.I won't be welding it, just wanted to get everything prepped for when it's done.I have got 2 of these, https://www.lifting.com.au/product/Z-0834PV000 in 4 ton versions.  They are going to be welded on the front, in line with the chassis rails, the main section is 1/4 inch with 3/8 mounts behind bolted to the chassis in 3 places, 2 shear and 1 tension.  They will be welded in a vertical position, as they give 100% rating at all angles and i am more likely to pull sideway's to a tree if needed, rather that up or down.Here's the bullbar, in progress.The question is, after reading other posts, is that a plate 1 inch bigger than the lug welding area is need with corners radiused, what thickness would you suggest and should i also get some thick angle welded each side of the bracket behind also?  The truck has a GCM of 7 ton at the moment but it hopefully won't be need at that weight in recoveries, i will also use an equalising strap on both lugs at once whenever they are used.I've probably missed some info but any advice would be appreciated.
Reply:Your lugs wouldn't open, but be conscious that often you will need shock for retrieval. My favorite tool for retrieval is a 30 foot 60000 LB nylon strap. I use it as a bungee cord. Recently it enabled us to retrieve a 36000 LB dump truck using a 8600 LB four wheel drive van! Sometimes you gain only inches per tug. It's all quite gentle except at the hooks.
Reply:It just opened, I suggest a 3/4" thick piece of flat stock basic cold rolled. Mount the lugs vertical.
Reply:Whoa, that bumper looks thin! I'd go with a 1/2-inch thick doubler plate, big enough to get real close to the 90-degree breaks in the bumper, and plug weld it too. I would use at least 3 flange to web gussets on the back side of the bumper. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:The bumper is not thin by any means, 2 people can, just, lift it into place, no problems in that area.There is already 3/8 plate, vertically, directly in line with the chassis, where the lugs will be put.  The rest of the bar isn't completed, obviously.  the corners will be cut on an angle from the edge inwards, with a step along the side which are also bolted to the chassis.  The steps are from the original bar that was ripped off getting recovered a couple of years ago.  It's been getting an engine transplant since.Here's the old bar style, the new one is way heavier.I was concerned about the jerking from a snatch strap, but with an equaliser strap used, i think, hope, it should be good to go.
Reply:Originally Posted by moose2367The bumper is not thin by any means,
Reply:It's 6mm or near 1/4 inch.  Most commercial bars, for smaller 4x4's are around 2mm.I was more concerned about the welds holding the lugs to the bar.There are 6 x 1/2 inch bolt holding the bar to the mounts and 4 x 5/8(i think) bolts and a 1/2 inch holding the mounts to the chassis.  There is a 16,500lbs winch mounted to the chassis too, not mounted to the bar, just the hawse fairlead will be.
Reply:I agree on the bumper  thickness appearing to be thin. How's the bumper attached ? I had to pull some cars out of ditches and use a tire to go between the two sling or chains. Sling threw tire to each one. Gives some stretching and easier on equipment. Just make sure the tire is strong enough.
Reply:When it comes to bumpers, and hitches you can't be too careful. I have over 70-tons of shear strength in bolts for the last hitch / bumper I built. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:The mounting is mentioned above, not sure on working out strength in bolts though.The bar thickness is also mentioned, do you think 6mm is thin?I don't have any pics of the mounts, will take some tomorrow, i'm in Aust, so it's getting late here.
Reply:Originally Posted by moose2367not sure on working out strength in bolts though.
Reply:Thanks, will check all sizes tomorrow and hopefully get back to you.  All bolts so far are CAT bolts, grade 8Thanks all for the info so far
Reply:The Little Jeep only weighs approximately 3,000 to 3,300 lbs., (curb weight). I have always been taught that a recovery point should be rated for 2 to 2.5 times the vehicle's curb weight. My recovery points are rated for 10,000 lbs.,. Your truck is a lot larger than my Little Jeep, yet your recovery points are only rated for 8,000 lbs., .... Am I missing something?Qualified & experienced at welding scrap metal
Reply:8000kgs, not lbs.  The lugs have a 4/1 safety ratio too