Custom Winch bumper on a Nissan D21 King Cab Hard Body - updated 8/2020

I Needed a place to out a winch, driving lights and some 6x9 lights So I made this. I reskinned the bumper later with DOM.

  

Revised with a face lift just before the SOA to 3 link suspension change.

Three SAS examples of bumpers:

3 SAS Nissans

Materials used: 

  • Harbor freight 9lb winch plate.$39.99 ITEM 3444-0VGA on website, not available at stores.

  • 8" wide flat stock 3/16 thick about 10' was purchased

  • OEM turn signals using OEM hardware. screws and clips. I had some extra steel clips.

  • OEM bumper brackets and hardware

  • 2x2 1/8 tube

  • 14mm bolts and nuts

  • Tube for sleeving the 2x2

  • Black spray paint

I really like my bumper, cost was under $100 but is more functional than an ARB. Very easy to install by myself. Uses 8 bolts. Nissan turn signals. Hilift can be use on it. Hidden D ring mounts.

.

Started with a Harbor Freight universal winch mount (web special order) Item 90476

Mocked up some cardboard brackets. Transferred to 8"flat stock. 

Made the brackets from same 8" x 3/16 flat stock. Just fine tuning the fit for levelness.

Welded the 1/4" winch plate to the brackets. 

 

I added a hole for the D ring.

Is it level??

Attached side to factory bracket AND winch plate. Sides are 8"x21" long. Top is 19" long cut into a triangle.

I welded some 4x8" flat stock to the inside to bridge to the OEM brackets. 4"x8" sides also added.

I cut some 2x4 stake pockets in half and welded inside the bumper. Turn signals are mounted using stock hardware.

Turn signals are recessed to prevent damage.

Made a slide in license plate bracket to free up space for the future winch. total weight 73lbs.

Updated to add lights. I cut some 1.5" tube at 23deg angles. drilled holes for wires. Added some light tabs. Then welded to top of bumper.

Update:  I re skinned the bumper and changed some things. I used 2x5 3/16 DOM and made some some cuts.

I cut the above sections off then welded them back in. See the wd21 winch bumper for more details.

Before and after

Then used new round nylon mounts for the lights. OEM uses square mounts.

Picked up a lighter fairlead on ebay. $20 new, no name in it.

I decided to move the lights from the bumper to the core support.

I then raised the whole bumper up for better approach angle. Made some new lower frame mounts.

Then added some D ring mounts. Added some new end caps.

Added some top 16 gauge sheet to fill in the open space. Its very useful space for tools.