my brother and i started on a bumper a few weeks ago. Just a stick of 5" C-channel cut and bent to fit. Hope you guys like

 

Looks like a good start. I hope you are going to brace it a bit more, or I fear that the winch'll rip it off... Also where is the roller? Not quite done yet?

 

I think the bumper is probably braced enough but i like the way Ed H. in his bumper build reinforced the frame. I will probably do that as well. And ya it's still in the build process. My brother takes industrial maintenance at his high schools votech so he only has about 2 hours to work on it each day.

 

You've to leave more gap between the bumper and the body. Bumper is attached to the frame not to the body and so they flex different. You'll smash your body if you leave like that...

David

 

Looking good i like the design, just a couple suggestions

definately do this it all flexes differently most likely your gonna break corner lamps and put a funky crease in the fenders

ok the yellow arrows concern me the top one because that plate is welded at a 90, the winch will not pulling in line with the frame or mounts it will bend or mostly likely crack those welds, put in some gussets(yellow triangles)

Second arrow i hope those washers are for mock up just because of obvious reasons a bolt only acts as a bolt when its threaded into something washers decrease strength significantly. just think of all the forces acting against all areas and you will see what i mean.

The green stuff i really like that i think im gonna do something like that on mine i have been trying to think of something for the sides of the bumper it seems kinda flimsy even tho its pretty stout i just wanna be sure its gonna hold up

The frame brace i put on my truck is the one i am really happy i did thanks ScottyC for bringing that to my attention i had a little to much faith in toyota on that one, i suggest you do this.

 

My computer at work kind of sucks, so I can't tell if you are using Grade 5 or Grade 8 hardware?
X2 on having more gap between your fender and bumper. Even with the gap I had on my Tacoma with an ARB, the flex rubbed the bumper until I lowerded the bumper about a 1/4":


I would recommend adding the bracing Ed H suggested. Overall looks pretty good. I know I can't weld for squat..but I would be sure to test your design at home before being buried up to the floor boards 20 miles off the highway

 

Yea i was thinking the same thing on the gap between the body and the bumper. We are gonna extend the mount to the frame and eliminate the washers and give it about an inch clearance at least. Then do some gusseting. What size hole should i cut out for the fairlead. I've got a roller that came with the winch when i bought it, but i eventually wanna go with a synthetic/hawse fairlead setup. does anybody have a measurement for this?

 

OC, I just noticed that it looks like you are missing a lugnut on that wheel.

 

Lugnut hell, missing a stud!