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Old 10-10-2009, 07:25 PM   #1
deepmud
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Default hidden hitch-mount winch bumper

I'm finally getting to use an idea I had a couple years ago - to make a winch bumper that let you use the winch as a hitch-mount, but looks pretty much like a bolted down winch when mounted to the front bumper.



Awhile back I found someone had done a "built-in" hitch mount, but it's more utilitarian than I wanted to do - ideally, it won't be immediately obvious the winch is removable.




I used the hitch mount steel ($25 a foot!) so that the stinger added to the winch can be changed - plus it makes a front-tow-hitch mount, useful sometimes. When it's all done, the license plate will be mounted to a piece of 2x2 square tube, it will hide the big hole in the center of the bumper, lol.




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Old 10-10-2009, 07:30 PM   #2
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Default Re: hidden hitch-mount winch bumper

that looks f-ing sick man, i love that bummer
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Old 10-10-2009, 07:34 PM   #3
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Default Re: hidden hitch-mount winch bumper

the hard part now is to get the front sheathed in sheet steel so it looks "finished".

I'm working with cardboard and foam
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Old 10-10-2009, 07:43 PM   #4
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Default Re: hidden hitch-mount winch bumper

yeah i bet, but when it's all done you'll have a real cllean bumper
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Old 10-10-2009, 07:45 PM   #5
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Default Re: hidden hitch-mount winch bumper

I think I can mount a mini-stinger/brush bar to the winch plate, to use to pick up the winch. It's HEAVY - I would swap to synthetic rope but it's out of my budget.
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Old 10-10-2009, 07:48 PM   #6
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Default Re: hidden hitch-mount winch bumper

Quote:
Originally Posted by BIG DAVE View Post
yeah i bet, but when it's all done you'll have a real cllean bumper
Thanks - it's taking a long time, but I think it will be a nice, "trick" design when down. The jeep owner has a rear reciever bumper so I'll wire in rear power and front power - and it then is easy to make an extension for power so it could be mounted on a trailer. That should make loading things a breeze.


edit: btw, I had Trevor/85Toyflatbed do all my welds - so they will hold! lol
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Old 10-10-2009, 10:21 PM   #7
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Default Re: hidden hitch-mount winch bumper

Pretty cool design. You're right it will be heavy!

Forgive me some days I am a little slow. If I understand right the winch plate is fastened to a piece of receiver tube and then you can stick a receiver into it?
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Old 10-10-2009, 10:29 PM   #8
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Default Re: hidden hitch-mount winch bumper

It's a neat idea. But i guess my first question is why? Do you wnat to be able to pull off the winch if you want to tow something with the front? If so why not just make the winch solid mounted with the Hitch attachment under it?

i don't know that I would trust that mount to hold with only 2 wells 2" apart. With the different types of pulls it will see.
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Old 10-10-2009, 10:44 PM   #9
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Default Re: hidden hitch-mount winch bumper

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Originally Posted by Bronco85 View Post
It's a neat idea. But i guess my first question is why? Do you wnat to be able to pull off the winch if you want to tow something with the front? If so why not just make the winch solid mounted with the Hitch attachment under it?

i don't know that I would trust that mount to hold with only 2 wells 2" apart. With the different types of pulls it will see.
Good point. A hard side pull is going to try and force the angle iron apart to the extent that the slop in the receiver pin allows it. Maybe an option is to drill the tops of the angle iron with say 9/16's holes then drill the winch plate with 1/2" holes and weld in from the top some 1/2" cold rolled 1/2" long into the winch plate. These pins would drop into the holes in the angle iron. Another option would be to put something like 1/2 square stock on the bottom of the winch plate at the outer edges of the angle iron.
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Old 10-10-2009, 10:51 PM   #10
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Default Re: hidden hitch-mount winch bumper

Quote:
Originally Posted by Bronco85 View Post
It's a neat idea. But i guess my first question is why? Do you wnat to be able to pull off the winch if you want to tow something with the front? If so why not just make the winch solid mounted with the Hitch attachment under it?

i don't know that I would trust that mount to hold with only 2 wells 2" apart. With the different types of pulls it will see.
the winch can be put in anything with a receiver hitch. the front-hitch open is just a bonus. It is not the main goal. I've seen plenty of receiver-mounted winches - it's amazing how "offset" some of them are, and they seem to be holding up for the users. I've also heard of few being stolen - it must be too tempting - so part of this is to make it "look" solid mounted/bolted down.

There is more than 2 welds , plus some gussets you can't see in the pics. I believe it will be about as strong as the typical class III hitch, except in overhead pulls, since there is no "top" it - if I have to, it will get two pins, but I think one will do it.

and ya, Snowbear, you got it
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Old 10-10-2009, 11:00 PM   #11
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Default Re: hidden hitch-mount winch bumper

Quote:
Originally Posted by snowbear View Post
Good point. A hard side pull is going to try and force the angle iron apart to the extent that the slop in the receiver pin allows it. Maybe an option is to drill the tops of the angle iron with say 9/16's holes then drill the winch plate with 1/2" holes and weld in from the top some 1/2" cold rolled 1/2" long into the winch plate. These pins would drop into the holes in the angle iron. Another option would be to put something like 1/2 square stock on the bottom of the winch plate at the outer edges of the angle iron.
Don't forget, this is just the substructure - I think the 1/8 plate that is getting wrapped around it will keep the channel from spreading.

I've thought about pins in the corners - for sure it gets some sort of rubber feet under the winch plate, so it will keep from rattling around
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Old 10-14-2009, 07:29 PM   #12
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Default Re: hidden hitch-mount winch bumper

Ill get with you when I get back to Anchorage, I got all the stuff to wire it up and a good deal on Synthetic line.
Eric
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Old 10-14-2009, 08:35 PM   #13
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Default Re: hidden hitch-mount winch bumper

version 2.0




it doesn't match any of the "real" angles on the bumper.






but it let me work out some of the thoughts I have on how to cut one out of flat sheet.




I think Grant's CNC plasma cutter is out of service, however. I think I'll end up figuring this out and then cutting it out of the plate with a 4" cutter disc. But if it was CNC, it would all one piece (except for the little triangle), and then I'd just score the back with the grinder, bend along the lines, and weld it up from the back.

Or so I figure

Working on version 3.0 - it will more closely fit to the subframe.

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Old 10-14-2009, 08:36 PM   #14
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Default Re: hidden hitch-mount winch bumper

Quote:
Originally Posted by CopperTopToy View Post
Ill get with you when I get back to Anchorage, I got all the stuff to wire it up and a good deal on Synthetic line.
Eric
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Old 10-14-2009, 09:33 PM   #15
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Default Re: hidden hitch-mount winch bumper

thats sick man. this winter i'm goin to build alot of bumper's for mine and my dad's rig's. 4 set's of them lol
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Old 10-18-2009, 09:23 PM   #16
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Default Re: hidden hitch-mount winch bumper



3.0 on the left.............................................. .................................2.0 on the right

3.0 was built up entirely inside, off the jeep. And - it shows



I'll have to re-do some angles. 22 1/2 degrees keeps showing up, accidentally. It's the angle of the lay-back on the front, came in without measuring. I'll deliberately use it again.





should I keep it as wide as the sheetmetal? This is not a hard core Jeep, but he may lift a little and go as big as 35's eventually.
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Old 10-18-2009, 09:37 PM   #17
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Default Re: hidden hitch-mount winch bumper

that looks sick man
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Old 10-18-2009, 09:59 PM   #18
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Default Re: hidden hitch-mount winch bumper

it sorta' has the swine flu lol

too close to the fender - and I have been trying to make the upper wings flat on top - but the fender seems to sweep up a little - I think if I match it tho', the bumper will just look "misbuilt".

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Old 10-18-2009, 10:09 PM   #19
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Default Re: hidden hitch-mount winch bumper

you know I sort of like version 1.0 - compact, tidy, good clearance of the fender, room for tires to be oversized

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Old 05-08-2010, 08:52 PM   #20
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Default Re: hidden hitch-mount winch bumper

I finally got to working on this project again. Partly I was lazily hoping Grant would put is CNC plasma back together. But he's busy


So it's all been on paper, and I realized I needed to make something I could "test" the idea without wasting a lot of steel. Fiber board works, sort of.



I realized I'd made the subframe too narrow at this point - it will require a bunch more work than to have done it right the first time.



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Old 05-08-2010, 08:58 PM   #21
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Default Re: hidden hitch-mount winch bumper

So I figured I was going to be able to do it with that pattern. I made up another fiberboard from the working model ( I actually did like 4 other "working models" - I used a full 4x8 when I was done).



I also made it 5" wider, hence all the scribblin'.



Next, I borrowed Trevor's awesome carbide metal saw.

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Old 05-08-2010, 09:04 PM   #22
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Default Re: hidden hitch-mount winch bumper

And I made these:



The carbide saw can cut channels to fold the steel on (it's 3/16) and that work great, but I need to cut deeper. After spending the afternoon working with some angle iron and a jack under my Expedition as a jury-rigged press-brake on the one side, I cut the channels deep on the other. It's really just to line things up, it gets welded on all the seams anyway. If I was using CNC plasma I would have just cut thru the bends leaving just a little to hold it together for welding.

I meant to get pics of the seam-cutting and bending but I was busy workin' I've learned a lot on this and the next one should go better. I'm not sure on my idea of making it in two halves - especially since it's not CNC cut. The center isn't perfect - luckily I get to cut 2" out of the center for the hitch so it should work out.

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Old 05-09-2010, 09:14 PM   #23
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Default Re: hidden hitch-mount winch bumper

I got more done.


I screwed up placement on bolt #2, I'm leaving it for now. It will be a weld/redrill fix later. But it's all tacked up. The space under each fender is even - that was harder than I thought - I think maybe the Jeep isn't "perfect .



And here is the subframe bolted to the bumper. I'll give the owner his rig back and finish...I HOPE...this week. I'm dying to see it done, so the winch can be pulled off and on, stuck in the back, stuck on a trailer, etc.

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Old 05-12-2010, 09:52 AM   #24
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Default Re: hidden hitch-mount winch bumper





getting closer......

There isn't quite enough clearance to run a 2" hitch thru the winch-mount and out the front of the bumper - it needs to move up about 3/16 - so my front bolt-holes are off I'll have to get Trevor weld 'em up and then I'll redrill it out again, after I shim the "skin" of the bumper up so it clears properly. Another thing I wish I had done right the first time.
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Old 05-12-2010, 09:57 PM   #25
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3 more hours work....oy.....
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