I think this is the last iteration. I'm itching to get off the computer and build this thing.
Current plan is to mount the winch feet forward on a Z shaped bent 3/8" plate. Frame mounts are 1/4". I modeled it first at 1/4" thickness, a single pull at a full 12K lbs will permanently distort it. This same design in 3/8" plate will survive many full load pulls. The frame horns might not, but the winch mount will. The center portion is 5" proud of the lower grill trim piece, roughly 3.5" past the frame horns. I think just enough to comfortably stand on. This should fit a truck with no body lift and trimmed fangs, but the winch clutch handle would need to be modified or clocked to the back. With a 1" body lift it will fit unmodified. The side "wings" stick out 2.5" proud of the front fenders.
I'm ignoring/assuming that the bumper skin will do nothing to help the cradle support the winching loads in the modeling, in actuality it will a little. The whole assembly weighs roughly 90 lbs without the winch.
Here's the winch cradle, front view:
Rear view:
The bumper is going to be a lighter gauge shell (3/16" I think) that attaches to the cradle with bolts top and bottom. The ends/corners will brace back to the frame in the factory locations.
Here's how the skin mates with the winch cradle:
Here's the FEA of the cradle made from .250" steel with a 12K load. All that red is no bueno. It will yield/deform in those areas the very first full strength pull.
Here's the 3/8" version with the same loading conditions:
small hot spots on the top in those inside corners, I will gusset/ radius them in to alleviate that.
Here's the stress distribution with a 12K lb load.
Here's the deformation projection, exaggerated 53X so you can see what it is doing: The red color corresponds to a deflection of .050" but it should spring back to the original shape.
Here's a view of the deformation from the side:
I neglected to save any good pics of the bumper skin, I'll post a few up tomorrow.
Going to send these pieces out for quotes, I'll let you know what it costs me to build one. Still willing to order quantities if anyone wants to save a few bucks on a winch bumper. PM me for a set of drawings if you want them.
Thoughts? What am I missing?
Current plan is to mount the winch feet forward on a Z shaped bent 3/8" plate. Frame mounts are 1/4". I modeled it first at 1/4" thickness, a single pull at a full 12K lbs will permanently distort it. This same design in 3/8" plate will survive many full load pulls. The frame horns might not, but the winch mount will. The center portion is 5" proud of the lower grill trim piece, roughly 3.5" past the frame horns. I think just enough to comfortably stand on. This should fit a truck with no body lift and trimmed fangs, but the winch clutch handle would need to be modified or clocked to the back. With a 1" body lift it will fit unmodified. The side "wings" stick out 2.5" proud of the front fenders.
I'm ignoring/assuming that the bumper skin will do nothing to help the cradle support the winching loads in the modeling, in actuality it will a little. The whole assembly weighs roughly 90 lbs without the winch.
Here's the winch cradle, front view:
Rear view:
The bumper is going to be a lighter gauge shell (3/16" I think) that attaches to the cradle with bolts top and bottom. The ends/corners will brace back to the frame in the factory locations.
Here's how the skin mates with the winch cradle:
Here's the FEA of the cradle made from .250" steel with a 12K load. All that red is no bueno. It will yield/deform in those areas the very first full strength pull.
Here's the 3/8" version with the same loading conditions:
small hot spots on the top in those inside corners, I will gusset/ radius them in to alleviate that.
Here's the stress distribution with a 12K lb load.
Here's the deformation projection, exaggerated 53X so you can see what it is doing: The red color corresponds to a deflection of .050" but it should spring back to the original shape.
Here's a view of the deformation from the side:
I neglected to save any good pics of the bumper skin, I'll post a few up tomorrow.
Going to send these pieces out for quotes, I'll let you know what it costs me to build one. Still willing to order quantities if anyone wants to save a few bucks on a winch bumper. PM me for a set of drawings if you want them.
Thoughts? What am I missing?
