Custom Winch bumper on a Nissan Pathfinder WD21

Updated 10/25/2010

I Needed a place to mount a winch and the following:

• 2 D rings

• 8k+ Winch

• 2 6" lights

• 2 driving lights

• License plate  

Tested

Materials used 

• 4" wide flat stock 3/16 thick about 6'

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

• OEM bumper brackets and hardware

• 2x5 3/16  tube

• 14mm bolts and nuts

• Black spray paint

I started off cutting 3 pieces of 2x5 tube to length. A slight angle on each cut. I welded together on a flat surface to make sure its all level.

I test fit to make sure room for a winch.

I cut out the inside for winch clearance.

I cut the sides at an angle.

I cut out holes for the turn signals

Then cut out back section for clearance. They will mount to the back wall of the tube.

4" winch plate added and some gussets

Grinding and sanding then added Hawse holes. I later replaced with and an aluminum one. This is a HEAVY steel one.

Oem brackets were a hair short and a little thin. I added some 1.5" x3" tube .120 wall.

Mocked up the height I wanted with a saw horse.

I clamped some scrap flat stock to tubes and set bumper on them. Then welded the tubes to bumper.

Now to remove saw horse and make lower bracket.

 Made the lower brackets, using the scrap I cut out off the turn signal holes. Drilled 2 holes and added to frame. Added a piece of 4" flat stock to connect brackets.

Made a template for a bracket that connect bumper to lower frame mount.

Added more leftover steel as a front brace.

License plate holder / work hitch.

All tacked up with 8 bolts holding it on.

Template for top.

Still to come more reinforcements, more welding, PAINT!

Updated. I never liked the space under the lights, So I took it apart and moved them up 1.5".