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I'm glad to see some interest so far! If I didnt want some constructive criticism I wouldnt have posted up here; it is good to question such things.
The design was analyzed at both straight-on pulling and angled winching loads. The boxing of the main structural support gives pretty good strength, so the side loading should not be an issue. We also did some calculations and figure that the bumper *should* be able to sustain a 5mph impact with little to no damage.
With regards to the bolt holes, I am thinking of making a thin aluminum plate to cover the mounting tab to act like a big washer to prevent the bolts from tearing or pulling through. More than likely the finished product will stay with the department as I am not sure how many we will end up making (depends how it holds up to real-world testing!), but if an extra one happens to disappear...who knows!
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84 4Runner SR5
22R, 5spd, 31" BFG ATs,custom bumpers
08 FJ Cruiser
Sandstorm, 6MT, All-Terrain Package, Rock Rails, BFG A/Ts
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