Should I just do it already?

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My recent project has been tearing into a perfectly good bumper in order to mount a winch plate.  The bumper is made from 1/4" uprights, and had a 3/16" 2x2 square tube between the uprights.  The bumper "covers" are all 3/16" stamped steel. It also used to have a 2" receiver in the middle.Well, I cut out the whole center section as you can see.  I cut down a 3/16" winch plate to fit between the uprights, and added a 3/16" 2x3 square tube under the winch plate.  After I got both the winch plate and sq tube cut to the correct width, I welded the two together on the sides (because you wouldn't be able to access those edges later).  I then tacked the assembly into the bumper.I was going to have a pro do the final burn in because of the stresses this will see.  It's going on a 2200 lb rig, and a 8000lb winch will be tugging on it.  I'm still learning, but I've had the itch to finish this project myself.  Is that unwise?  I figure if I'm not trying I'm not learning.  At some point I need to learn to trust myself I suppose.My welder is a Lincoln Pro Mig 140, right now I'm just using .035 flux core.  I'd weld this thing top bottom and sides, and have ground the edges at angles to help penetration.  I have some left over 3/16" to practice on before going after the bumper.  Thoughts?Here is how it started:Here is where I'm at now:I'm going to make some extensions to fill the gaps here:Those that say "If it ain't broke, don't fix it" just don't understand!Fast-Cheap-Reliable:  Pick two.
Reply:I'd say if you're comfortable with the appearance of your own welds, do it. You're going to be your biggest critic. An 8,000 lb winch should pull that little thing through a knothole and then some.  As a side question, ruling out your welds, have you thought about what your weak point will be if you get hooked up good and really reef on it at an angle?
Reply:There is some overhead and some vertical up.  If you can't weld out of position, its a good time to learn, THEN do it.Become a Pro!Be sure you have good power going to the machine.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I would minimize the out of position welding, though I would like to keep it mounted as long as possible during the welding so help minimize warping.I'd weld every seam between the existing bumper, sq. tube, and winch plate.  With the edges ground down a bit, I don't think penetration will be too big an issue, especially since I can get to the top and bottom in most places.I guess I'll take some scrap to butt together and try different settings.  I'll try to rip the pieces apart like David did in one of his tests and see what the joints look like.I don't mind trying, I just don't want my winch to rip itself off.Those that say "If it ain't broke, don't fix it" just don't understand!Fast-Cheap-Reliable:  Pick two.
Reply:Why a Winch? Just pick the dern thing up and move itEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Sometimes I just pull it in/out of the garage if I don't feel like starting it.  Kinda nice I do have one question.  What's the best way to get deep into the gap the rounded edges of the square tube leave against the winch plate?  The seam marked with the red arrows. . . In the near future, I'd also like to add some gussets which I've outlined in blue.  I don't think strength will be an issue, only the welds.Thanks guys!  Those that say "If it ain't broke, don't fix it" just don't understand!Fast-Cheap-Reliable:  Pick two.
Reply:For the Pre beveled  horizontal weld, use small rod, maybe 3/32.  Go deep take your time to fill the groove.  Use enough heat, hold the rod perpendicular (straight in) pointed up a little.  It will fill if you go slow. Learn to weld out of position.  It aint easy, but once you master it.....David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:You could lay like maybe a half inch round bar in there, and fill it in.......I did that making my bumper.2 pieces of 3 inch together wasnt going to be strong enough, so on the backside, I laid a length of round bar in there, and burnt that in......worked purdy good!!!!Miller blue star 2eLincoln 175
Reply:Originally Posted by David RFor the Pre beveled  horizontal weld, use small rod, maybe 3/32.  Go deep take your time to fill the groove.  Use enough heat, hold the rod perpendicular (straight in) pointed up a little.  It will fill if you go slow. Learn to weld out of position.  It aint easy, but once you master it.....David
Reply:David, he's using a Lincoln Pro Mig 140 and fluxcore wire.Edit; all within 5 minutes! 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:Bolt the Winch plate to the Cross member and call it a day- the 140 isn't going to do much but just pile wire in the "Groove".Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Oops.  You already have small rod.    Just do it!  Use all the heat you can handle or all you have.About all you are going to get is 100 amps out of the pro mig 140.Be sure to get rid of the paint and mill scale first.That may be a small rig, but it has a full frame.DavidLast edited by David R; 06-20-2008 at 07:38 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I've cleaned the metal everywhere I planned on welding (though it may not be visible with the cell pics). Would a small rod be OK as a filler?  Maybe I'll just bolt it instead.  I don't think my welder has the juice to do anything but fill that gap with wire.Those that say "If it ain't broke, don't fix it" just don't understand!Fast-Cheap-Reliable:  Pick two.
Reply:Glad you guys convinced me to do it.  Got started this evening.  Lowered the wire speed a bit and cranked the power.  The horizontal welds looks really good (very impressed myself), but some of the vertical and out of position stuff looks a bit rough.  I only have a few small spots (probably less than 3" worth of weld total in 3 or 4 locations) that I want to hit with the grinder and re-do.The only stuff I have left is on the underside towards the engine.  I've got to remove the bumper to do it.  That's when I plan to clean up a few of the sloppy areas. I'm fairly confident that even the sloppy stuff will hold.  It looks like it went in deep, it just doesn't have the prettiest bead in some spots (namely where I hit my previous spot welds).  I'm going to fix it anyway.More pics in a bit. Those that say "If it ain't broke, don't fix it" just don't understand!Fast-Cheap-Reliable:  Pick two.