Blazer winch bumper and questions.

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So I have decided to tackle a project that I have wanted to do for some time, to build a winch bumper for my 87 blazer.I did a bunch of drawings, looked at some bumpers that others have built and kind of merged a couple that I liked (although none of them were actually on a blazer) so I am kind of winging it as I go.SO....... this is my blank canvas.As I looked at it I didnt like the idea of having my bumper held on by only two bolts but given the area I was kind of stuck.  So I figured I would box in the end of the frame to give it a bit more strength and also give me room to add a third mounting bolt..... like this.As I proceded from here I hit a snag that I thought I would as you all about.  The frame rail is kind of twisted a bit and not really truely rectagular, especially on the drivers side.  They are square to each other though.  I tried twisting it a bit to straighten it out to no avail.  So I mocked everything up with it as it is.  It is really only about 1/4 inch tweaked counter clockwise which I can compensate for fairly easily.  My question is should I worry about getting it perfect of just leave one of the brackets tweaked a bit.  I have heard that Chevys are known to do.This is what I was thinking for the finished look mocked up in cardboard.
Reply:ignore the fact that the one side is a bit droopy...... I couldnt get it to hang right even with duct tape.  That wont be a problem with the steel one!
Reply:like the idea of boxing in the frame ends  the cardboard standin is a cool way to check things out before you start the the real deal.  best of luck. hope to see pics of the finished project soon.
Reply:Good idea on the cardboard mockup!Next, just how strong-n-beefy are you trying for?  And are you going to put the winch on top, in front, or behind the front?I'd say to watch out for tucking the bumper too close to the body panels.  Any biff-bash-sideload onto the bumper and even if the bumper itself doesn't move or dent, the bracket(s) or frame rails moving/twisting/whatever will mean body damage.How thick is the plate you plan on using?  Steel, aluminum, diamond-plate, what?If you go  'thinner' on the plate, you can/must add more strategic bracing/gussets/framework.  If you go 'thicker', you can usually use less overall framework and have less overall gusseting, but usually end up heavier overall.  Or a combination of heavier plate where needed/desired and thinner plate where less 'meat' needed (like the outer corners).How about a reinforcing mounting bar/bracket that goes to the frame rails and then the bumper attaches to the mount bar/bracket?  How's this for beefy - rectangular cross tube (blue) [1/4 inch wall or better] capped in heavy plate (red) [hmmm, 1/2 plate or better?] tapped for mounting bolts in between the frame rails with outer gussetted [gussets not shown] sandwich plates (aqua) [1/4 inch plate or better] all welded to a front bracket plate?  Mounting bolts to attach to the truck go from the 'outside' through the holes in the aqua plates and through the holes in the frame rails and into the tapped heavy red plates.  Extend the red and aqua plates back far enough to beef up the frame rails and give enough space for the appropriate size and number of mounting bolts desired.  The blue rectangular tube is sized to go back as far as the plates as well.Unless it's just the picture, I see what you mean about the driver's side frame rail being twisted.  It would be nice to straighten it, but without a press and dies I think it will be difficult to do without ending up twisting other things as well.Looking at my possible mod, I'm not all that happy with the load path with the aqua plates there.  Without fussy shimming between the plates and the frame rails, there is no real bolt clamping between the members especially if you make the plates and gussets big and stiff enough to minimize bending/deflection.  Which means that the load through the frame is all shear with no clamping force.Hmmm, how about skip the aqua plates and just go with the thick inner red plates and the cross tube?  A little less fussy fitting, but still the mounting tube will have to be custom fit to your truck and frame relatively carefully. Attached Images
Reply:yep cross brace,,rail to rail...body clearence ,,remember D-ring hooks and a place to step up on the bumper
Reply:After boxing in the frame I was going to make "brackets" that would go around (rectangels) the frame rails out of 3/8" plate with  grade 8 bolts attaching each bracket to the frame rail.  The winch is actually going to sit behind the front plate kind of hidden.  Sort of like this except I was going to put a piece of plate on that just slid over the top and locked to keep the winch a bit more secure.I was going to use some more 3/8th plate for the winch to mount to with angle iron along the seams for extra strength and riggidity.  I do like the idea of a bar in the back between the frame rails to add some strength. Also I am going to utilize the side mounts like so, but even with these any straight on impact is going to be directly absorbed by the bolts.I wasnt sure about the body clearance...... I was thinking of about an inch space all the way around should be ok but open to suggestions.
Reply:So I spent yesterday working on the bumper.  Most of the morning was spent tinkering with the mounting and doing the winch box.  Came up with this.Doesnt look real pretty but is as solid as a rock (it is a chevy )After that the rest went pretty easy.  I didnt think to take pictures till I was half way done with my grinding so you get weld pictures from one side and ground on the other.  BTW I ground the welds to make it look all smooth and pretty.  that front picture still confuses me because it looks like the winch box is curved on the bottom which it isnt at all.  Got to love cameras.  Also I know my welds are WAY rough, its amazing how rusty you get when you have welded anything in almost 10 years. Attached Images
Reply:looking good
Reply:Looks great
Reply:looks nice
Reply:bad a$$http://www.aloumac.ca/
Reply:Looks good , must add a fair bit of weight to the front end.
Reply:Looks great!And you have 2 ground clamps, welder and plasma? Or what are you using?Left one looks just like my 175 clampMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:That bumper has the look of being much stronger than the frame it's connected to. Just like so many before, the weak point becomes the frame. I still like it though! City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:I like it! Looks great for off roading. I also like the large surface on top (good enough to stand on when working under the hood(as compared to the stock bumpers these came with).
Reply:Thank you for the compliments everyone!I was so worried starting this project, but after getting going on it I feel it is coming along nicely.  I do agree that the frame is the weak point of the whole thing which is kind of sad but I cant fix that too much.I am guessing that the bumper with all the mounting equipment and the winch is probably going to weigh in a little over 200lbs but not sure till I finish and toss it on the scale.  I purposely made sure I had a step on the bumper.  With the 38's and a 6" lift I either have to have a step stool or try to stand on the wheel to work on it.  The two ground clamps are one for the welder and one for the plasma.  I did a little "trimming"
Reply:yes you need a place to stand ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,and sit your beer
Reply:Have you, or someone before, re-geared the differentials for the 38's?City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:re-geared in what way?
Reply:re-geared = change the gear ratio to take into account the larger diameter of the (new) tires.Example:  original gear ratio was 3.55 with 31-inch tires used.  Changing to 38-inch tires without changing the gear ratio means you have about the same new effective ratio as if you had 2.9 gears with 31-inch tires.  Same effective ratio with the 38's as for 3.55 with 31's would be 4.35 in the diffs.  Same effective ratio with the 38's as with 3.73 with 31's would be 4.57 in the diffs.
Reply:had a buddy go to 4.56's from 3.07's with 38's,,,,,,picked up 3 mpg and was WAY better to drive on and off road
Reply:What they said! Taller tires don't let your engine work at it's most efficient range in the rev band. It utilizes it's best hp and torque when geared correctly for the tire size. I need to check my own truck as well, though I only have 33's on it.City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:The guy I bought it from said that he had it regeared to 4.10 and had the speedometer recalibrated.  To be honest though I havent made it that far back to check it out.  I swapped out the engine he had in it with a 350vortec with the carbeurated intake.  Havent done a whole lot with diffs in the past so I will probably have to have a friend come over and walk me through checking them out.  At the rate I am going though, I am going to be lucky if I can get it done by hunting season.
Reply:Looks great plenty strong if you think you might want some off road lights nows the time to cut a couple of holes and weld some tabs for mounting.
Reply:I am going to put some lights on it along with some D rings and still need to cut out the opening for the roller fairing.Originally Posted by tanglediverThat bumper has the look of being much stronger than the frame it's connected to. Just like so many before, the weak point becomes the frame. I still like it though!
Reply:This pic is with 529 ratio and 38sThis one is 456 ratio with 36s   Two inches makes a whole lot of difference in performance.  I absolutely didnt want to spend $ on adding my third set of ring and pinions,however, one day in the woods and I found I had to. weld it like you own it
Reply:more torgue
Reply:Here is the finished project.  Been done for some time but never moved the pictures over from the camera.  Ended up modifying a brush guard that I picked up to finish it off.  Enjoy!
Reply:Now that's a bumper!!! Bet it rated at more than 5mph.Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready