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Winch plate-bumper

From 1992 Ford Bronco, documented by fodder.

66 photos
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1992 Ford Bronco - Winch plate layout on 9/32" steel plate. As you can see, I tweaked the plan a few times while sketching it out. 1992 Ford Bronco - Inner and outer cuts completed on the winch plate, but still some cleanup to be done. Next up is the vertical tabs to line up with the bump… 1992 Ford Bronco - Chopped up Curt 13310 laid over the winch plate. The horizontal edge of the old square tubing needs to be trimmed further back, as I added… 1992 Ford Bronco - First test fit. You know it's light when just three little spring clamps can hold it snugly in place. That and the friction against the bum… 1992 Ford Bronco - Rear view of the rear angled supports added and all the mounting holes drilled. Also, the meaty Expedition tow hooks that will be used. 1992 Ford Bronco - Expedition tow hooks installed. I couldn't use the top nut bracket because it would have to pass through the bumper mount tab, and I couldn… 1992 Ford Bronco - Second test fit, fully bolted up. Everything lined up properly, which was a bit of a relief. The sway bar hasn't been reconnected to the mo… 1992 Ford Bronco - Next up, deciding what the front face should look like. 1992 Ford Bronco - Front face mockup added to the winch test fit. 1992 Ford Bronco - Receiver added in and all spot welds filled in fully ... only to realize after that the main plate had developed quite a bow. It warped exa… 1992 Ford Bronco - Rear view of the hitch receiver addition. 1992 Ford Bronco - The torch didn't heat the main plate up enough to remain flat once cooled and the clamps removed, so I cut the front face and used it to pu… 1992 Ford Bronco - Front face tacked in place and fairlead on for a better representation of the final product. 1992 Ford Bronco - Top view. 1992 Ford Bronco - Side view. Rear angled braces will be added at the ends of the front face. 1992 Ford Bronco - Fairlead cutout completed, braces added to the back of the face plate. 1992 Ford Bronco - Test fit 2 ... oops, it's not the full 33.75" between the bumper mounts' front portion. Will have to either move the face plate supports in… 1992 Ford Bronco - Opted to shave the face plate supports to clear the bumper mount brackets. 1992 Ford Bronco - Much better now that Test Fit 2 actually fits! No issues lining up the 8 bolt holes after the main plate deflection issue. 1992 Ford Bronco - Bumper and sway bar bolt brackets cleaned up and painted. 1992 Ford Bronco - Top tabs added to the face plate for Phase 2 (bumper wings) tie-ins. 1992 Ford Bronco - Arr. 1992 Ford Bronco - Final welding completed, cutouts added (subtracted?) for 3" LED cubes. 1992 Ford Bronco - Completed, top view. 1992 Ford Bronco - Completed, bottom view. 1992 Ford Bronco - Close-up of the final pass welds. 1992 Ford Bronco - Close-up of the final pass welds. 1992 Ford Bronco - Close-up of the final pass welds. 1992 Ford Bronco - Close-up of the final pass welds. 1992 Ford Bronco - Close-up of the final pass welds. 1992 Ford Bronco - Close-up of the final pass welds. 1992 Ford Bronco - Spent a bunch of time chipping away the weld slag and splatter. 1992 Ford Bronco - Primed and ready for paint. 1992 Ford Bronco - Painted and installed. It's actually pretty easy to mount up without the use of a jack (or helper) with the tow hooks off. It doesn't budge… 1992 Ford Bronco - I did some rust treatment on the frame horns, as evidenced by the black sections (less visible to the naked eye). 1992 Ford Bronco - Installing the winch was a major PITA, and annoyingly did a fair bit of damage to the winch plate's new paint, but I eventually got all the… 1992 Ford Bronco - Winch installed, damaged paint touched up ... break time before working on the LED cubes install. They're the biggest challenge of all, due… 1992 Ford Bronco - Yay, the cover fits on now that the sheet metal tab is painstakingly bent back. 1992 Ford Bronco - LED cubes finally in place and plugged back in. The best solution I could come up with is oval head allen bolts up through the bottom (hex… 1992 Ford Bronco - Quick 'n dirty bumper wings added to visually fill the space, and get an idea what shape will work well. 1992 Ford Bronco - Bumper wing, stock profile. 1992 Ford Bronco - Bumper wing, stock profile. 1992 Ford Bronco - Bumper wing, likely profile. 1992 Ford Bronco - Bumper wing, likely profile. 1992 Ford Bronco - Bumper wing, stock vs angled profile. 1992 Ford Bronco - Tightened up the dimensions of the bumper wing top "plate" and started boxing the front profile. 1992 Ford Bronco - Front view. The temporary 2x4 gets in the way of perfect placement, but it's quite useful as a support piece for the mock-up! 1992 Ford Bronco - Closer to completion. I'll probably give the lower portion a little sharper angle and tweak the wheel well outer corner. 1992 Ford Bronco - Front view. I'm not quite happy just yet with how it intersects the winch plate, but a little more angle to the bottom portion should help… 1992 Ford Bronco - Extended the bottom portion to mesh better with the winch tray. Not quite as streamlined as the previous version, but better integrated. Th… 1992 Ford Bronco - Side view of the extended bottom (and finished outer corner). It doesn't interfere with the LED field as much as I feared. 1992 Ford Bronco - Tidied up the template to get more precise lines and copy measurements over to the steel. Propped up close to level to remove some of the g… 1992 Ford Bronco - Side view of the final version. 1992 Ford Bronco - First bumper wing completed; test fit is close but needs a bit of fine tuning at the wheel well. 1992 Ford Bronco - Initial test fit. The outer portion needs to tuck in tighter and sit a bit higher in the wheel well. Otherwise, it fits as desired. 1992 Ford Bronco - Frame horn mounting method, using spare bumper mounting brackets that don't require getting a wrench on the backside. 1992 Ford Bronco - Backside view of the bumper wing. The pool of weld material at the far left was added to level that better relative to the winch tray's top… 1992 Ford Bronco - Shimmed the frame horn mounts to get the desired position, but not happy with the line it forms at the front of the wheel well, so that wil… 1992 Ford Bronco - Adjustments made, mounted at three points (in two planes) now for a very sturdy fit; just need to do some final welding of the new pieces. 1992 Ford Bronco - Minimal blockage of the LED cubes. I think they have a 30 degree flood pattern, so there probably won't be any cutoff. 1992 Ford Bronco - Trimmed the part that extended block-like into the wheel well, but still needs some fine tuning. 1992 Ford Bronco - End trimmed to flow better with the wheel well. 1992 Ford Bronco - Measurement notes for the bumper wings. Final tweaks not reflected. 1992 Ford Bronco - Painted the first bumper wing (was starting to flash rust) and started in on the other side. Following a different approach on #2, building… 1992 Ford Bronco - Side 2 taking shape. Tried out an idea I've been kicking around for a mid-top brace that doubles as a flip-up license plate bracket. 1992 Ford Bronco - Front view of a white 1992 Ford Bronco equipped with an aftermarket bumper and winch.