A few years ago I decided my dodge needed a winch. I would also need a sturdy mount for the winch. There were several available that I liked but they were all very expensive. My favorite was the Buckstop bumper like Stacy installed on the red dodge of the truck show several years ago. I want to say it was like $1600 or so. I dont have that kind of money for bumpers. So I pulled the plastic factory bumper off and started my design process.
I built a wooden model to test it out first. Then I made it all in steel. I had to make brackets to mount the bumper to the frame. Then I made a box that the winch sat in. Everything else is used to offer crash protection for the front end and to cover all the stuff you dont normally see on the front. The mounts were made out of 1/2"plate. The box for the winch is 1/4". The outside parts were made from heavy sheetmetal and bent in a brake. Then I used flatbar and angle to reinforce them. The brushguard part came from a dodge dakota brushguard. It happened to be the correct width to fit nicely. Originally I didnt want the brushguard, but figured it might save the radiator if I smacked a deer or such.
I wanted to keep the weight down at first but it got heavy quick. I would say the bumper probably weighs over 100lbs and the winch is another 100lbs. You can really feel it on the front end. I like always having the winch on the truck, but next time I make a truck bumper I will make the winch removable. I am not a fabricator by trade but I do some welding. This is probaby the most complex project I have built for a vehicle. It could have turned out better but I am happy with it.