Step 4: Finalize the Design

Using your preliminary design sketches, combine your design concept with the modeled (or carefully drafted) geometry and measurements of the front components of your truck.  If you're like me, this will take quite a bit of time, thought, and bouncing ideas off of other people.  Being able to view my design in a 3-dimensional format proved to be a great visualization tool for me, and I made a lot of design revisions based on being able to see the design from many viewpoints.

My final design combined bent tubes and steel plate.  The 3/8" steel plates that extend upward from the frame horn mount plates are quite unique.  Their truss-like appearance really distinguishes the bumper from other ones on the market.

Another unique feature of this bumper is that the design allows for the winch to be unbolted and removed through the front of the bumper (after unbolting and removing the bash plate).  Winches are very heavy and add a lot of extra weight while just driving around town, so it's nice to have the option to remove it when you're not out wheeling.  Many winch bumpers require that the entire bumper be removed and the winch inserted or removed through the back side of the assembly.  This provides theft protection but means that the bumper is more or less permanently installed.  When I install a winch on my bumper, I plan to use vandal-proof Torx screws and nylock nuts. 

Some bumper designs have a winch plate assembly that is separate from the rest of the bumper and bolts directly to the frame of the truck.  Some plate bumpers allow the winch to be bolted onto a flat space on the top of the bumper.

You may find the steps following this one (Step 4) helpful in learning more about other design factors--in addition to winch mount plates--that influence the overall bumper design.  You can then make more informed decisions about what you need and want in your bumper design.
<p>loved this article! I just bought a 2006 nissan frontier and it is bone stock. I am planning on building a front bumper, rear bumper, and bed cage for it soon and this helped give me some great ideas. I do not have access to a water jet but am going to school now for industrial design/ machining and have access to solidworks and a cnc plasma table. Will definitely look forward to referencing this &quot;how to&quot; for help when i am ready. Thanks!! </p>
CNC plasma will work great! I'd love to see what you build! - whether you share it publicly on here or send me some pics via PM. Have fun and best of luck in your endeavors!<br><br>PS - I STILL need to do a rear bumper :'( You should see what my stock one looks like after the Rubicon trail ?
<p>Made by Boztec</p>
Correct, I designed this with the owner of Boztec in 2012 and he did the fabrication
<p>I have advice, an instructable is when you explain how you built it, how you designed it.. how you welded it together,, not why you needed it,,, it cool and all, but, I realy wish people would make instructables,,, explaining how to do something,,, thats what this site is all about........</p>
Looking for the exact project deets, for the bumper pictured here. Any advice?
Wow, well done. Please share dfx. files
I would like the measurements for an off road front bumper for my 1971 ford f250 highboy. One that can fit a winch . my email is justinhorn89@gmail.com would like pics of the bumper with the measurements. Thank you much
very nice, please share your dfx. files
Me gusta, chica. I have wanted to do the same to my truck for a while now, I think I'll start in the morning. Can't wait to see the rear.
I might be designing a front bumper for a Ford F350 this summer. Will post an addendum to this 'ible if I do.
<p>Did you design that F350 Bumper? If so, what year?</p>
<p>Great work! I want something similar for my Frontera, but in my country it is not legal to use &quot;homemade&quot; parts on car, everything have to have certificate. What a shame. If You know, what are You doing, it can be better and more safe than aftermarket parts with certification.. Thanks for sharing!</p>
This is great! Would you share the dxf files? I would live to make one for my fj!
Great design. Very well designed and executed! Looks better then the ones I've seen on the market.
Bumper, that is, the rear bumper. <br>
Ha! - nice one.
Wow, excellent design and execution! Kind of makes me want to go buy a off road vehicle just so I can build a bumper. Thanks for posting.
Thanks! Next on the list is a rear bumper. I kinda messed up the stock rear bumper in Moab... oops!
Thanks, blkhawk! I submitted it for the Metal Challenge contest--or rather, attempted to--but after encountering an issue with the website entry submission process, it didn't post my entry until 12:00am last night--about 10 seconds after the cutoff. I'm petitioning to have it allowed into the contest! :)
This is a cool project!

About This Instructable




Bio: I've been making things since I was a little kid, starting with furniture for my stuffed animals. I love power tools and wrenches and ... More »
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