Dimensions of front fame ends?

[R_Lefebvre]

I'm starting to think more and more about just fabbing up my own front bumper because none of the ones on the market really do everything I want.

I haven't taken the front bumper off yet to have a look, but I'm just wondering what the dimenions are on the front of the frame? Do they interface well with any standard tube shapes so you can easily make bumper mounts that slip on? Or do you end up making a box with custom dimensions?

I like the design of the Trek front bumper best out of all of them but it's still not quite right.

Related to this, why does the Trek use a frame sleeve
http://www.trekoutfitters.com/discovery/extra%20pics/ds2framesleeve.jpg
instead of just having the winch basket integral with those sleeves?

Is the RTE similar?

Just wondering if some sort of frame sleeve is mandatory on the Disco vs. just having the frame mounts integral with the rest of the bumper.

 

[I HATE PONIES]

01 DII frame ends are appx- 3" wide and 4" tall. If you box the mounts they will have to be nearly exact measurements. Keep in mind that box will not crush. The bolts will not tighten with 1/4" plate that is solidly welded to the bumper in a solid box.

Also once you see the angle need to clear the front clip with no crush cans you will see that a true box is nearly impossible anyway.

 

[evergreendisco]

What are you looking for in a bumper that you are not finding with any of the aftermarket bumpers?

 

[R_Lefebvre]

I want a rigid winch mount and recovery points. I also want more front end coverage than the RTE. I want the look of the ARB with the functionality of the RTE. I also don't want to wait all summer when the time finally comes to do something.

 

[I HATE PONIES]

What are you looking for in a bumper that you are not finding with any of the aftermarket bumpers?

Dynamite first post new guy. You rocked the Rover world with that one.

 

[I HATE PONIES]

I want a rigid winch mount and recovery points. I also want more front end coverage than the RTE. I want the look of the ARB with the functionality of the RTE. I also don't want to wait all summer when the time finally comes to do something.

The ARB look will be tough to get with plate. Unless you use thin stuff the weight will be super high. If you do make one like an ARB the angles from the frame horns can be made straight due to the overhang. You will lose approach angle and front end clearance though.

If you want an ARB or TJM style I would say just keep an eye on the for sale markets. They still show up occasionally for pretty cheap. Mostly guys upgrading to the RTE. The amount of material cost and time spent building one would probably net around the same as a good used one. I made mine to get my own look and function. If you want someone elses look and function then be patient and wait for someone to sell.

The non-airbag ARB's can be modified to accomplish what you desire.

 

[R_Lefebvre]

I would like to keep the weight down, and considered aluminum, but my TIG welder is only 180 AMP which limits me to 3/16". Protection comes before the weight so I don't know if that would work. I was thinking of making it more out of square tube instead of plate. Something like 2x6 box section or parallel 2x3 twinned.

Also wanted to make the A frame portion out of box section instead of round.

Can I see a picture of what you did? Curious.

I'm not as concerned about the approach angle. If I want to take a really hard trail, I'll just take the bike.

 

[I HATE PONIES]

I'll see if I can find a pic. Just be aware that mine are not finished yet. I am awaiting the winch before I weld in the inside plate mounts. It should give you an idea though.

 

[R_Lefebvre]

You weren't able to just plan for how the winch would mount? Just curious, because I could be in the same position. I could start work this weekend, but I don't have the winch yet. The winch dimensions are published though.

I was thinking of having the frame mount longitudinals come right straight forward and protrude out the front and be capped off with DB hooks mounted on the ends. Weld the winch frame section between the two longitudinals. The winch would be nicely front, center and high with good accessibility. Approach angle would be compromised by all this of course, but only in the center. The side pieces would be set back with less overhang, similar to the Trek.

The A frame would use 2x4 box section for the verticals (thicker in the longitudinal direction), but with a taper cut, tapering to 2x2 at the top. Probably 2" round tube welded at the top. 1" round to finish out the brush guard.

What guage steel were you using?

I'm thinking square aluminum tubing might be stronger than any open, plate steel design.

 

[I HATE PONIES]

Couldn't find any so I snapped a couple more. These are once again NOT finished but they will give you an idea of what you need to do. This bumper is made from 5" C channel. 7" might look better. The tube is a bad idea because the DII grill is not straight like the DI grill. If you do straight tube you will have a large gap. If you cut the grill straight it will look better but there are metal lips on the bottom that will have to be cut as well.

The only one on here to see it so far in person was Lordkenyon. I don't know if he is still here but I got the impression that he liked it.

 

[robertf]

I just got a hell of a deal on a winch this weekend so I'm in the same position. Here's my rough plans so far.

 

[R_Lefebvre]

Is that a Romulan space ship?

Sorry, that background is funny.

 

[I HATE PONIES]

I wasn't sure what winch I would end up with. Now that I know, I can get close but it will be here soon so I will wait. I wan't to remote mount the solenoid and sink the winch body into the grill. I didn't want to start cutting without see how it looked.

 

[R_Lefebvre]

Ponies, I see what you mean about the angle from the horns, and the bottom of the grille.

I think my design would cure both problems. The longitudinal members could come straight forward with no angle. I know this would reduce approach angle but I think I can live with that. I'll have to check it out though.

The grill thing is easy since I would be making the side parts seperate from the center section, they could be welded on at the right height. I wouldn't be using a tube straight across. Think 3 sections. Center, and two sides. Different heights, different overhang between center and sides. Think Trek bumper.

 

[rovercanus]

RTE bumper.

 

[R_Lefebvre]

Ponies, what's the thickness on your C channel?

Real nice work on that by the way. Looks pretty well proportioned, nice and tight to the body. I actually want more protrusion though.

 

[I HATE PONIES]

Ponies, what's the thickness on your C channel?

Real nice work on that by the way. Looks pretty well proportioned, nice and tight to the body. I actually want more protrusion though.

It is 1/4" x 5" C channel with 1/4" plate for the rear to box it. I kept it that close to allow for the winch tray to stick out and in. It will go up and out on the same angle as the mounts to retain approach angle (in theory).

 

[robertf]

Is that a Romulan space ship?

Sorry, that background is funny.

found out how to do fancy reflective backgrounds, here's the craddle. The bumper will be a skin over this.

 

[I HATE PONIES]

found out how to do fancy reflective backgrounds, here's the craddle. The bumper will be a skin over this.

That is some cool stuff.

 

[R_Lefebvre]

Yeah, that looks not bad. That was similar to one of the ideas I had, but I don't have the ability to cut those plate steel ears so I was trying to stick with tube.