Budget Boost - Bumper Fab & winch

I took off the chrome tube bumpers and nerfbars. In the meantime, I got a stock set of bumpoers until I could fab my own (thanks Pete). I also installed a 2" Rubicon Express Budget Boost.

For the heck of it, I also bolted my Hi-Lift jack to the front bumper, just for something different.

Here are how my bumpers start out, raw 2x4x3/16" rectangle tubing. This is going to be a front bumper.

Here is one of the ends cut. I just kinda eyeballed this angle, and then duplicated it. It ended up being about 66* if you like the look, and make your own. I also left 1 1/2" flat.

Here is how I capped the ends. I took 2x1/8" flat stock, clamped it in a vise 1 1/2" down, and pounded it with a hammer till it kinda matched the angle I cut. I then tacked on the short end, then pounded it flat. This made it curve at the edge, and gave a more rounded finished look.

Here is one of the ends. Capped, welded, and grinded.

Here is the finished bumper, minus brackets and d-rings, in white primer. I then mocked this up with the winch and plate, only to find that I had to make clearance for the winch fairlead. It sat back and below the plate.

...But that's nothing a plasma cutter can't fix (Thanks Rich). We cut the holes for the d-rings, and cut a clearance notch for the winch fairlead.

And here is how I fixed that. I measured and cut the hole by and extra 3/16". I then took a piece of 1x1 angle, flipped it in, welded it, ground it, and also cut little squares for the corners, and made a nice sealed recess.

Here it is. Almost finished. Brackets, d-rings, and fairlead clerance all done. Hanging and drying in white primer.

Here it is. Finally. The brackets and d-rings came from Big Daddy Off Road. The winch plate is Blue Torch FabWorks. The winch is Warn XD9000i.

Now I need to make a rear bumper... sometime.

DIRECTORY:
*page 1 - Intro & details
*page 2 - stock pics. removing bling
*page 3 - small 2" lift. front bumper fabrication. bumper and winch installed.~>you are here
*page 4 - Suspension install
*page 5 - Driveway Flex
*page 6 - Hood Flames & PSC Rockers
*page 7 - Action shots (Paragon 3/19)
*page 8 - 8.8 Axle swap **NEW**