Got the bumper just about finished today, I need to cut a couple of small angle reinforcements and fit up the wings. The winch mount, frame mounts, pull points, and skin are all welded out. Did everything with my little 110V Hobart. Tripped the 20 Amp breaker in my garage 4 times. The duty cycle on these little welders is limiting when you have a lot of wire to burn.
Here's a few in progress photos.
Pull points, 3/4" plate welded to the 1/4" frame mount. I ground a nice big V and filled them in and ground it smooth with a flap disc.
4 1/2" bolts per side attaching it to the frame, I tacked the nuts in place inside the frame rail. I used 3 factory holes and drilled a fourth per side.
The winch mount separates from the bumper. It is held in place with 3/8" bolts. I match drilled the winch mount to the bumper skin and tacked the nuts on that as well.
Welded everything that touched between the frame mount and bumper skin. Don't look too close at those welds, they're OK but I'm not a professional.
Here's how it sits on the truck, it fit right back on perfect after welding. I did fit it up and tack it together mounted on the frame so it wouldn't be a fight to get it back on. My truck sits slightly higher on the passenger side, that angle is not an optical illusion, I think i'll try to shim the drivers side core body mount and line that up better. The lean is courtesy of the dented front fender.
It is just right for standing on.
