In addition to making my own front struts Ive also been making a rear winch bumper for my EA81 hatch.I put the winch in the rear for a couple reasons.
1. My car is a hatchback,with the addition of an EJ22,transfercase,and front diff my car was front heavy as it was.No sense in adding any more weight to the already overweight front end.
2. For self recovery purposes a rear mount winch is often superior to a front mounted winch.Most of the time when you get stuck its alot easier to back through the tracks you already made than it is to go forwards into the muck.Most of the time I probably wont need the winch because I never wheel alone.On the other hand If I get stuck somewhere they can't go I need to get myself back out.
So without further ado.I had to reinforce the rear "strap down" points because they are not up to the task of recovery.Mine were ripped off.To reinforce the mounts I cut them out and used 2" thin wall square tube to make up the channel part of the frame. 2" angle iron was then welded to the square tube and the body to tie into as much sheet metal as I could.
After the reinforcing it became clear that my actual bumper mounts would have to be made from 1.75" thick wall square tube because it fit tightly in the reinforcements.the bumper mounts extend 20" into the "frame" on each side.They will be secured by 3 bolts on each side. The bumper is 2x5x.125 box tube,because I am mounting a winch to the bumper it needed a hole cut in both sides for the cable to pass through.So I cut a hole about the size of the roller fairlead.I also boxed in the hole on the sides and top to get back the strength that was lost from cutting the hole and to give the cable a smooth surface to slide against.
The actual winch mount is a 3/16" plate welded to the bottom of the bumper,it extends towards the front of the car and bolts to the rear most gas tank crossmember .Obviously that thin stamped steel crossmember will not take the load of winching so I ran some support pieces from the middle of the plate down to my rear diff mount.The support pieces are made from 1.5 x .085 wall round tube.To attach the support pieces to the car I crushed the ends of the tube in my vice then welded them closed.From there they are bolted to some 2x2 angle iron that is welded to the diff mount or the winch plate.
here is the rear bumper
this is the winch mounting plate.To get the right clearance the floor hat to be cut,this also allows me to watch the cable spooling in.
here is my 5000 lb harbor freight winch.
here is a couple pics of the support brackets.
I am going to add some angle iron behind the support bars on the mounting plate for some rear impact protection.I am also going to weld on some D ring shackles to the bumper,I haven't done that yet because the car is not sitting level and I don't want to mounts to be crooked.The roller fairlead will get mounted over the hole for the winch cable.