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Originally Posted by Cliff
Is this setup I am imagining strong enough to support a winch in use? With 4 bolts holding the entire bumper to the frame, will I need to strengthen the mounting?
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Yes, I think so but you will need an additional crossmember in front of the original one. The new X member can connect to side plates bolted to the frame rails using the four nuts intended for the original bumper.
There is another hole along the same path in the frame rails where a third nut/bolt could be placed. This nut could be welded to a plate to provide a means for anti-rotation and the assembly could be fished through a larger hole next to it.
I have been studying this area recently for a new bumper I plan to make. As I recall I decided that one of the steering gear mounting bolts would need a clearance hole so it could be accessed without removing the new bracket.
I was not planning a winch so my frame brackets were to be flat plate. If I were to use a winch I would consider using channel for the frame brackets. This will stiffen the structure and may be needed when pulling at angles. On the other hand flat plate may be better as it might give way on a heavy side pull preventing damage to your frame.