I figured I could chime in and share with you guys my front bumper build. I am a fabricator by trade(3years) learned how to draw on autocad at work my fiddling around during breaks and I was able to draw this myself. I cut everything out on the CNC plasma table with the exception of the shackle holes which were drilled to 1 5/16.
First, I made a cardboard template. I needed to make this bumper different from any other production bumper so if I ever did want to take an order or two, I wont have a problem. It would have been a lot easier if I could get a computer drawing of the truck itself like most companies do, but this should work just fine. Keep in mind because this is the "prototype" you will see some things that needed to be hacked or changed a little so bear with me.
3/8" plate for the frame mounting. I also cut out a 1/4" backer plate which will act as a washer, but distribute the force better. I am not a fan of the stock frame horns, but in order to make the bumper universal theres really nothing you can do.
1" X 5" wide shackle plate. this will be gusset or boxed into the 3/8 plate. this way you will be pulling directly from the frame. Some bumpers pull from the bumper which is not ideal.
took the main section and got it to where I want it to sit. In the picture I had it hit the grille. the holes in the frame are slotted for lots of adjustment when the bumper is finished.
The main section is 1/4" and the rest will be 10ga. This truck is a daily driver so I didnt really have a need for carrying the extra weight. I feel 10ga will be plenty thick considering there will be bends and weld joints close enough together is would be difficult to bend or dent. 137 lbs just in steel. I am shooting for under 150lbs.
I will be running two piaa 520 6" driving lights and 2 piaa 510 4" fog lights under the headlights. No grille gaurd for me as it is a pain to work on the engine with them.
I will be running a 10-12k portable winch. I will only be using the winch a few times a year so its not ideal for me to be lugging around the additional 100 lbs plus MN winters would kill it in no time. I will run (2) continuos duty solenoids, one for the front and one for the rear so I dont have power going to the bumpers all the time. 350 amp quick connects will be mounted on the bumper. sq. tube will be welded from the hitch revceiver tube over to the shackle plates to the stress is distributed.
Also have a waterproof block heater plugin similar to Marinco's.
The reason why I only did one side of vent holes is because I need a spot for my license plate, quick connect and block heater plug.
Hoping to get the rest of the bumper bent up soon!