Chris - Thanks for the link! That looks very-much like the bumper I'm installing. That guy has several videos of his Sporty on YouTube. And watching them has been helpful in planning the mounting of the bumper so it can hold a winch. That has been my most-recent hurdle because the bumper will mount right under the front grill (slightly). However, this is a Jeep bumper (TJ and YJ). There are a few inches of stick-out on a Jeep's frame rails, where the bumper mounts. SmittyBilt designed it with the idea that a winch would mount behind the cross-rail of the bumper, not in front of it. So I stopped by the shop where I bought the bumper and gamed it out with one of their techs. It will be easy to shift the winch forward to clear the grill-area with some simple modifications and still have a solid mounting. It looks like I can stay with the same plan. Thanks again for the link! <img src="/forums/images/graemlins/kewl.gif" alt="" />

Just wanted to post a quick update on the front bumper... I finally decided to keep things "simple" and just extend my front end to match a Jeep. That may sound complex. But it actually seemed easier to me because it eliminated the need to mod the bumper and winch mounting plate. So now I have an extra 4" of frame behind the new bumper. I'm not done. But I have reached the point of bolting on the bumper, with the new frame extension welded up solid. <img src="/forums/images/graemlins/kewl.gif" alt="" />


Here's the new body mount design. Its 1/4" steel tubing. I cut it in half down opposing corners (diagonal) to make two brackets. I'm going to add some gussets to reinforce the back end. But there's a bit more work to do there, which will be discussed once I get some more work done on it.






I used 4"x4" steel tube (1/4" wall) to extend the frame off the bracket. I plan to box the ends so the extensions will be stronger.




The bumper mounts on a 2"x4" cross bar (3/16" wall) that connects the frame rail extensions.






I assembled everything with Grade 8 bolts. Once I had it all bolted up and square, I welded it all up. So this mod is permanent! <img src="/forums/images/graemlins/zombie.gif" alt="" /> My welds aren't pretty. But they are solid...




So here's a photo of "how far I've gone" with the project. You can see from the side view how the extension gives more room for the winch. I feel safer having gone this route than trying to hang the winch off the end of the bumper. I may have lost some approach-angle. But I think everything will perform better, overall, in the end...





More progress-pics in a week! <img src="/forums/images/graemlins/scared.gif" alt="" />

<img src="/forums/images/graemlins/cheers.gif" alt="" />

Look at it this way. You kind of replaced the crumple zones that were cut off before. <img src="/forums/images/graemlins/butwiggle.gif" alt="" /> Well not really cause it will take one heck of a hit to get these 4x4 blocks to crumple.

Nice work so far.

Logansportage <img src="/forums/images/graemlins/patriot.gif" alt="" />

OK, here's my weekly update on the front bumper...


The top of the body mount-bracket was a lacking enough surface area to support the lift block. So I added a top plate of 3/16" steel to fully-support the block and ran it across the extension to provide additional strength...




As noted in my previous update, this frame-mod is permanent. I welded up the nuts on the grade 8 bolts before proceeding to box up the extension...




Consistent with my tendency to over-engineer everything I build, I added a bit of 3/16" plate to brace the inside of the extension tubes. The idea behind it was to reinforce the tubes against the pulling force of a winch. They also add another layer of protection against compression, though I have no intent to test the latter theory... <img src="/forums/images/graemlins/scared.gif" alt="" />




Then I boxed up the ends with more 3/16" plate, which was cut ground to fit slightly-inset within the tube. Now the tubes are all closed on both ends...




Being that the top surfaces of the body mounts are now flat, I fabbed up some "C" rings from some rod that I had laying around. The body blocks will set inside of the rings...




I was having so much fun welding, I decided to cap off the 2x4 tube... and I justified it with the idea of keeping the inside dry and protected from rust... <img src="/forums/images/graemlins/notooth.gif" alt="" />




Here's a look at the lift blocks bolted up. Everything went together well. FYI - I was going to buy one more piece of the acetal round stock to go with remaining piece I had already. But I had to buy a foot. And that would have been another $50. So I bought a foot of 3" round nylon scrap for $10 and had it cut to size. It machined alright, but not as cleanly as the acetal. I went with the nylon because the tech at the plastics shop said it would handle the compressive forces much better than HDPE and UHMW, which he said are softer (more so in the heat). I know HDPE and UHMW both work fine for the application. But the scrap was cheap and it was gray, not white. Hey, it worked... <img src="/forums/images/graemlins/cheers.gif" alt="" />




Though I think the mounting brackets were strong enough as they were, I added some 3/16" plate to support the backside, so they were similar to the original mounts...




Here's a side view of the bumper and winch plate mounted. They are actually bolted on!!! Now you can see how the winch will mount. I've added 6" to the length of the frame, to include the bumper's mounting rail (it sits under the winch plate). And that will position the winch just in front of the grill... <img src="/forums/images/graemlins/zombie.gif" alt="" />




And here's a view from the front...




I'm happy with the progress so far. Everything feels solid. I've started working on fabbing up a grill from expanded metal and closing up the areas from the bumper to the fenders. The stock grill and filler pieces below the headlights were already in bad shape. So I figure it will be easier to just add some steel to fill it in... and it gives me another excuse to weld!!!
<img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/patriot.gif" alt="" />

Here's the weekly-update...

I've started working on building up the grille and closing up the areas under the headlights. And then I realized that I needed to install the universal fender flares I had picked up long-before buying the bumper(s). So the fender flares were the project for the weekend.

I have a 25 ft roll of 4" flare-stock (Pacer brand, I think). And it's a surface-mount product. So it requires about 1.5" of flat surface for mounting. The front fenders don't have that much flat area at the wheel-well. But I was able to fix that with a dead-blow hammer (mallet) and some body dollies. <img src="/forums/images/graemlins/shiner.gif" alt="" /> It isn't pretty. But I was able to mount the flares. I was also able to rough-out a grille from expanded-steel sheet. And then everything came to a grinding halt because I had to figure out how to attach the new grille and parts below the headlights. That process was complicated more by the body damage and the way it was repaired. And that, in turn, lead me to go "shopping" at a wrecking yard for a functioning hood-latch and a stock AC condenser fan (the fan in the photos above isn't stock... took me all weekend to figure that out! <img src="/forums/images/graemlins/angry.gif" alt="" />). Fortunately, I was able to get those parts today... only to realize that when the dip-<img src="/forums/images/graemlins/ignore.gif" alt="" /> that "repaired" my Sporty after the accident (several years ago) used a non-Kia fan, he cut off the Kia connector and spliced the wires to the non-Kia fan and connector. Now I have to go back to the bone yard and get the connector for the Kia fan... <img src="/forums/images/graemlins/baby.gif" alt="" />

Anyway, here's a few photos of the project. It's still a work-in-progress...








<img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/patriot.gif" alt="" />

Here's a quick update on the front bumper...

I spent much of the weekend working on getting the placement of the headlights "better" than before - this due to the slight-shifting of the front end due to the wreck. And I decided to hit a bone yard and get another fender for the driver's side. The original fender had some stress-cracks in it from the idiot that did the original repair... His idea was to bend the fender to fit the body where it attaches below the turn signal. Not good. So I made an extension-tab to relieve the stress on the new fender at that location. Mounting the fender flare to an already-weakened fender was too much for it. And the thought of wind drag left me fearing the fender might give out while driving. The new fender went on fairly easy... and I pulled the little under-the-headlight trim pieces from the donor vehicle too, which will make closing up the gap from bumper to fender that much easier. And all of that filled the weekend... though much of the time was spent eye-balling the appearance and making little adjustments until I felt everything was good enough. <img src="/forums/images/graemlins/cyclops.gif" alt="" />

Here are some pics...











<img src="/forums/images/graemlins/patriot.gif" alt="" />

Time for another update...

I was able to get the grille done and made good progress on closing up the area below the headlights. I still have some minor stuff to do before painting. But I'm getting close to being done with the front bumper... until I get a winch, at least. <img src="/forums/images/graemlins/notooth.gif" alt="" /> And then I can work on the rear bumper, the OBX diffs, and replacing the brakes - all before the Thanksgiving holiday! <img src="/forums/images/graemlins/scared.gif" alt="" />

Here are some pics of the progress. Sorry about the "headlight trim" shots. It was getting dark when I finally had everything bolted on for a photo... <img src="/forums/images/graemlins/baby.gif" alt="" />

Grille...







Headlight trim shots...










<img src="/forums/images/graemlins/cheers.gif" alt="" />

WOW!!!!

How much weight fave been added to the front syspension?

Greetings Fokion - I'm guessing that the weight will increase by about 100 pounds per end, likely less, not including the weight of a winch. The front bumper is lighter than the rear. But I've added more steel to the front than the rear so I can mount them. Once I get my Sporty back on the road, I'll know how the added weight effects the ride. The 105AA springs in the rear are pretty stiff. So the rear shouldn't be a problem. The front... guess we will see how the stock springs handle the weight.

That said, here's my update from the weekend...


I have the front almost done and was able to paint the new steel. I used Rust-oleum truck bed paint (spray), which has a textured finish. I wanted to use a durable paint. And I think that type of paint will do the job. I guess time will tell. Here's a photo of the finished paint job:





Once the paint was drying, I started on the back bumper. And that was much easier to work out than the front since my Sporty's never been damaged in the rear. I've removed the stock bumper's mounting-plates welded to the end of the frame and fabbed a set of "U" brackets that wrap around the ends of the frame (don't have any photos of it yet... but you can see some of the lower-portions of the brackets in the photos below). The "U" brackets extend up a few inches and are topped with a cross beam, to which I've attached 2 pieces of 4"x4" steel tubing (3/16" wall). The 4x4 tubes provide the mounting points for the rear bumper. I have the mount tack-welded and will pull it off to do the final welds and give it a coat of paint. Then I'll mount it up, weld it all to the frame and do some touch-up painting before the rear bumper goes on for good. And now for the pics... <img src="/forums/images/graemlins/smile.gif" alt="" />










If all goes well, I might have everything done before November 23rd and my trip to SoCal, to include the OBX diffs. <img src="/forums/images/graemlins/scared.gif" alt="" /> But the weather is getting cooler and the rainy season is starting (had rain over the weekend and temps in the 50s... Fahrenheit). That makes it hard to weld and paint. <img src="/forums/images/graemlins/angry.gif" alt="" /> But I'm making progress!!! <img src="/forums/images/graemlins/kewl.gif" alt="" />

And now for the weekly-update...

Spent the weekend finishing the rear bumper mount. I was able to get it finish-welded and coated with primer. The next step will be to paint it with truck bed liner, then mount it on the frame, weld it in place and do some touch-up painting on the welds. On another note, I was also able to confirm that the Smittybilt tire mount (swing out) will clear the rear hatch. So I picked one up and will bolt it on once the rear bumper is on for good. <img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" /> If all goes well, I will have the bumpers done next weekend (yes, both!). That's my last chance before the holiday-trip to So Cal. Unfortunately, I won't get the OBX diffs installed in time for the trip. But I should be able to get the brakes done... which I really need to do because the big tires were already causing the front brakes to fade. I know the extra weight from the bumpers will only make it worse. <img src="/forums/images/graemlins/scared.gif" alt="" />

Here are some pics of the mount, just before I capped the open ends of the tubes and went wild with the primer. For reference, the "U" bracket consists of a 2x2 upright with a short length of 2x2 extending from the bottom (which slides into the stock tie-down bracket on the frame and will be welded in place), another short length of 1.5x1.5 extending above it (will be welded to the top of the frame) and a piece of 2" c-channel between the two extensions (slides into the open-end of the frame and will be welded in place). The rest of it should be straight-forward, I think... <img src="/forums/images/graemlins/baby.gif" alt="" />








<img src="/forums/images/graemlins/patriot.gif" alt="" />