4x4 & MPV Driver - 40% subscription discount

Isuzu Trooper Owners Club UK™
Isuzu Trooper, Rodeo, Bighorn, Mu & VehiCROSS Owners Club
 
 FAQFAQ   SearchSearch   Watched TopicsWatched Topics   MemberlistMemberlist   UsergroupsUsergroups   RegisterRegister 
 ProfileProfile   Log in to check your personal messagesLog in to check your personal messages   Log inLog in 
CalendarCalendar  ITOCUK Club ShopClub Shop  ITOCUK Classified Ads serviceClassified Ads
ITOCUK HomeITOCUK Home   dynamic online chat serviceChatrooms  Yellow Diamond ClubsYellow Diamond Clubs

Tube winch bumper build, with pics


 
Post new topic   Reply to topic    Isuzu Trooper Owners Club UK™ Forum Index -> Modifications
View previous topic :: View next topic  
Author Message
Philip A.
**


Joined: 28 Nov 2012
Posts: 53
Location: East Africa

PostPosted: Sun Jul 21, 2013 15:02    Post subject: Tube winch bumper build, with pics Reply with quote

I've built a number of full-plate winch bumpers, mainly for Toyotas, but my preference goes to tube bumpers. They are usually lighter, and I find them better looking.

Here is the work in progress on my Trooper.



Let's start with the brackets' mounting points. These are badly rusted, humidity trapped between the original bumper's brackets and the chassis has done them in.





Cut off the rotten plate...





Cut, drill and weld a replacement plate. Holes on the mount in front of the chassis are drilled to take M12 bolts instead of the original M10.





40x40x4 angle, temporarily bolted and spotted in place for further measurements





And we can try the winch on. This was gracefully donated by my SWB Land Cruiser (soon to be sold, but the winch will stay in the family...)





But wait a minute. That's the usual "Wait a bit..." when you're tinkering with something, and all of a sudden you see a better way to do it. Instead of having the winch mounted on the bumper, with all the associated weight pounding on the bolts (which are working in shear in this installation), why not build a fixed winch mount, and have the bumper on its own? That would be stronger, and the bumper will be easier to disassemble when needed. Here we go...







I know, the winch is the wrong way around. But like this, the cable pulls from under the winch, more inline with the chassis and the attach points. The drum engagement lever will be cut off, and another front-facing one fitted.

From here, we start putting what I call the "winch cage", which is the core of the tube bumper. The brackets have been extended and now hold on four M12 bolts on each side. Together with the flat sheets, they will cut to measure and shaped when all measurements fit with everything.



Back to top
View user's profile Send personal message
Google
Sponsor





PostPosted: Sun Jul 21, 2013 15:02    Post subject: Google Ads keep this community free to join!


Back to top
jacksdad1963
*******


Joined: 26 Jul 2011
Posts: 1939
Location: Oldham, Lancs

PostPosted: Mon Jul 22, 2013 16:30    Post subject: Reply with quote

Looks good, stick with it mate!  Very Happy
_________________
1999 3.0 TD Duty SWB
3" Body lift, 3" suspension lift, diff dropped, balljoints flipped, extended panhard, Tree sliders, Superwinch, +2" Pro Comps, 33" Mudders: Nearly finished!
Back to top
View user's profile Send personal message AIM Address
Philip A.
**


Joined: 28 Nov 2012
Posts: 53
Location: East Africa

PostPosted: Thu Jul 25, 2013 18:38    Post subject: Reply with quote

Added the hawse supports in front of the drum





Bent the 50mm tubes for the main bars, and spot-welded in place, with temporary supports






Bending template with various scribbles... The template was originally taped horizontally on the side of the winch cage, extending around the body's corner, and the outline of the top tube drawn by hand. forgot to take a picture.





Check from the side that all lines up





Start putting the bottom tubes in place





Continue with same. Compound curves are difficult to get straight (pun intended) on a manual bender, so it's easier to cut the bends separately and weld them at the appropriate offset.



Now, I'm not going to enter into details, but between the last three pictures there is an impressive amount of cussin' and hittin' and general merryment... In the Trial and Error process, Error comes first by a long way!



It starts coming together

Back to top
View user's profile Send personal message
Red Robbo
Lifetime member
Lifetime member


Joined: 17 Feb 2008
Posts: 4129
Location: Where ever I happen to be in my imagination but mainly Far East Sussex

PostPosted: Thu Jul 25, 2013 18:42    Post subject: Reply with quote

As JD said..... Cool
Back to top
View user's profile Send personal message
eithan h
Moderator
Moderator


Joined: 11 Dec 2005
Posts: 8195
Location: oxfordish

PostPosted: Thu Jul 25, 2013 23:14    Post subject: Reply with quote

is the top tube not touching the wheels in the last pic?
Back to top
View user's profile Send personal message
Philip A.
**


Joined: 28 Nov 2012
Posts: 53
Location: East Africa

PostPosted: Fri Jul 26, 2013 5:38    Post subject: Reply with quote

The tubes are not yet cut to final length, they will be cut in line with the wheel arch.
Back to top
View user's profile Send personal message
Philip A.
**


Joined: 28 Nov 2012
Posts: 53
Location: East Africa

PostPosted: Sat Jul 27, 2013 18:04    Post subject: Reply with quote

High tech Laser Tube Aligning Device





Everything is now almost ready to go for painting. I had half an idea to go without bull bar, but upon insistence from the crew we tried one on, and it fits nicely. But let's give to Caesar what is Caesar's: the crew had seen the pics of the bumper that I took as inspiration, Markymoan's neat bumper... Good design, simple and effective. Good looking too.













Back to top
View user's profile Send personal message
Hunter
Lifetime member
Lifetime member


Joined: 08 Jul 2010
Posts: 614
Location: Scottish Borders

PostPosted: Sun Jul 28, 2013 10:49    Post subject: Reply with quote

Good build thread  Cool
_________________
Back to top
View user's profile Send personal message
Philip A.
**


Joined: 28 Nov 2012
Posts: 53
Location: East Africa

PostPosted: Fri Aug 16, 2013 19:32    Post subject: Reply with quote

Disassembled and thoroughly checked the winch. Like most of its brethren, although looking quite scruffy from the outside, it had seen very little use and the innards are in like-new conditions. Repainted, and mounted. I'll install a synthetic rope in replacement of the original cable. The winch mounts double as hi-lift jacking points.





The bumper is now complete. There will be finishing touches, like plates to join the wheel arches and the front wall, tidying of cables, etc.



Back to top
View user's profile Send personal message
Red Robbo
Lifetime member
Lifetime member


Joined: 17 Feb 2008
Posts: 4129
Location: Where ever I happen to be in my imagination but mainly Far East Sussex

PostPosted: Fri Aug 16, 2013 19:39    Post subject: Reply with quote

V  Cool
Back to top
View user's profile Send personal message
rabbitt
Moderator
Moderator


Joined: 13 Jun 2006
Posts: 1192
Location: Nuneaton , midlands

PostPosted: Sat Aug 17, 2013 8:27    Post subject: Reply with quote

ill take one in black please

no winch required lolz
Back to top
View user's profile Send personal message Visit poster's website MSN Messenger
ecp
Lifetime member
Lifetime member


Joined: 23 Aug 2010
Posts: 465
Location: DURHAM

PostPosted: Sun Aug 18, 2013 3:09    Post subject: WB Reply with quote

fab thread, great pics and top notch job m8 well done
Back to top
View user's profile Send personal message
lorrick
*


Joined: 17 Apr 2015
Posts: 31
Location: Near Halesworth Suffolk

PostPosted: Tue Apr 21, 2015 18:11    Post subject: Reply with quote

I was going to ask if you would make me one as I have been looking for some time, then I saw your Address, a bit top far to travel  Very Happy But really looks great.
Back to top
View user's profile Send personal message
Display posts from previous:   
Post new topic   Reply to topic    Isuzu Trooper Owners Club UK™ Forum Index -> Modifications All times are GMT + 1 Hour
Page 1 of 1

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum


All contents © Hobson's Choice IT Solutions Ltd 1997 on
Powered by phpBB © 2001, 2005 phpBB Group