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="" />