This is a project to make the most simple yet functional stubby winch bumper from scratch using all new materials. So I'm looking at this really simple AEV stubby on Quadratec (which by the way they never have in stock) and I'm thinking I'd just fab one up that would probably be better anyway. Anybody have the dimensions of the typical Warn, Ramsey or Superwinch mounting bolt holes and the minimum depth I would need where the winch mounted away from the leading edge?



In addition, I think it would be finished off nicely with the Rugged Ridge D-Rings (hopefully I could get them in black) or the PureJeep shackles (funky homebuilt looking).

Material Prices:
Appox. 4 feet of 9x6 3/16 steel rectangular tube from Clackamas Steel: $75
8 heavy duty mtng. bolts: $20 ?
1 can of Krylon Wrinkle Finish $5

Extra Prices:
Rugged Ridge D-Rings: $139 (maybe less because thats the stainless price)
PUREJEEP Crawler Bumper D-Ring Shackle Mounts $89.99

Gonna get my buddy at the Body Shop to bring in his Plasma cutter because I figure I'll need to do a cut-out on top for the winch and maybe cut gaps on the top and bottom part on either side for clearance. I measured a trashed out OEM bumper bar I took off a wrecked JK and its exactly 6 inches wide so the 9x6 size should work good. This leaves a solid 9 inches down below to mount the winch which should be sufficient. Without the D-Rings I can't imagine this whole thing costing more than one Franklin. Any thoughts from other people who have tackled this?

 

Has potential. There are some threads of people modding up TJ bumpers, might be worth considering to.

 

Have you seen this one?

 

Yeah, couldn't miss it since their advertisment cycles through the forum header all the time. Sure its a simple stubby and a good deal at $189 but first of all, I don't like anybodys logo laser cut into my bumper. You want me to advertise in such bold fashion for you then pay "me" to put the bumper on my JK is kinda how I feel. Thats what turns me off to a good portion of the bumpers out on the market actually. Especially FabFours Hardcore bumper that would certainly allow a big stick to poke right through its huge logo.

Secondly, instead of ending at the top edge my design would continue to wrap around and go back on either side of the winch cut-out about 9 inches, similar to the Rugged Ridge stubby or perhaps the Pure Jeep stubby. This would allow me to at a future point to add a custom fabbed grill guard bar with light tabs which I also figured would only cost less than $30 worth of new steel. I'm going to call them next week and maybe drive out next Saturday and pick up the steel. I'm going to keep track of my labor time as well so I can figure that into the cost somewhat.

 

Sounds like a good plan, but I have a few suggestions that may save you some time and $$$.

Instead of using 9x6x3/16 box tubing ( I assume you'll just be cutting away the part(s) you're not using?) consider using 2x6x3/16 c-channel for the bumper, and using some 5/16 or 3/8 plate for a seperate winch plate, with maybe a 2" lip bent up or down at the end closest to the grille for strength. This can be bolted to the frame and bolted to the bottom of the bumper. I think you could probably do this for half the price of that 9x6 stuff. Maybe even less if you can find those pieces in their remnants pile.

While you're at your meatal supplier, you can buy some plate and flat bar to build the shackle mounts from. If you're not confident with your welding, have a pro weld the mounts to the plate. This needs to be strong! These can be made for probably $10-$20 in steel, plus welding if you have to pay for that.


Unless you just need/want stainless ones, d-rings are way cheaper at the hardware store, or Tractor Supply if you have those in your area.

Either way, keep us update on your progress.

edit: here are a few pics of mine,made from the same size c-channel.

 

But that ones never in stock,, which is the point now to make one similar.

 

I never wrote down any measurements when I built mine (see sig link), but I am thinking all winches have the same mounting patterns. Otherwise it would be a problem for all of the after market bumper companies out there. Basically what we did was made the box for the whole winch then set the winch into it and marked for the holes. After that it was a matter of cutting out the fairlead hole and mounting the hawse.

FYI...if you look at the link you can see mine in "stubby" form....I almost left it like that and then decided I wanted the tubes to finish it off....

Good luck either way....custom is the way to go...

 

Yeah, I like what you did there but didn't you have to drill holes in the frame to mount the winch plate you made? I'm leaning towards the one piece design because of its sheer simiplicity plus I'm thinking that it would also be stronger.

Seeing as I'm an Auto Body Tech the welding thing isn't a problem if I wanted to make the style like you fabbed up which is real similar to the PureJeep one. The problem is if you look at the Skunkwerks shackle or the Rugged Ridge Plate and D-Ring shackle its a different design that doesn't look like anything I'd want to take the time to fabricate. I'd rather just buy the Rugged Ridge one as it looks real similar to the Skunkwerks shackle mounts and plus the hardware store ones make to much noise banging around up front. I've looked at probably 30 or more farm and heavy machinery websites for shackle d-ring mounts similar to the Skunkwerks and Rugged Ridge ones but never had any luck.


Nobody beat me to anything really. Similar idea just different goals which is more functionality, simplicity and the lowest possible cost for DIY JK people with nothing more than a drill, saber saw and a grinder. I saw the Skunkwerks pictures the day they hit the net. Thats not the point though really. Go back and read the second sentence at the start of my thread and you'll see that I pointed out that it was made by AEV and sold by Quadratec. In addition, it is not really cheap at $249 plus $29 in shipping and I've called several times and they never have it in stock. Needless to say, I'd seen several other threads with homebuilt stubbies and I thought I'd try to make an "IKEA" flavored bumper at the absolute lowest cost using all new materials.

 

..Wow...that looks solid!!!

 

Go for it. I have been using the AEV winch mount and Expedition One Rubi skid for about 5 months. Works excellent offroad- light wieght, efficient, high clearance. Ideal for crawling.

I got the D-ring holder from Nates 4x4 for $50/pair unpainted.