I posted this on Pirate4x4, but thought I would share with the Hummer boads.
So here is what I started with-
I'm about 75% complete, and just started taking pictures. Sorry about that.
First I made a mold out of cardboard.. kind of hard to work with, so I went to Home Depot and purchased some aluminum plating to make a better mold.
Got the mold measured and all cut-
Everything fit nice and snug.
Next up was cutting the metal. Went to K&K and picked up around 40lbs of 1/4" and 3/16" plate and started grinding away. Got all of the cutting done last night!
Some of the pieces-
I jacked up the winch between the frame rails then drilled the mounting holes to the front of the bumper. The top piece slid right in and then I bolted up the front for a test fit-
Mmmmm... nice and tight. It actually is a tighter fit than the stock piece-
Then I drilled the remaining front holes and bolted it up. I am losing 1" of approach angle.. not too bad of a sacrifice for a winch. Plus this thing should be solid enough for me to slam down on it if I slide off of a rock.. couldn't do that to the stock piece.
