Join Date: Dec 2001
Location: Belleville, Illinois
Thanked 22 Times in 17 Posts
That'll work. With metal 1/4" thick you can finish it entirely by grinding. Use 60 or 80 grit to get close. Then switch to a 120 flap disk to finish it. As long as your welds are decent there will be plenty of material left after finishing.
And you really don't need 1/4" tube there - 3/16" is plenty. 1/8" is probably plenty. Going too strong is a common mistake, though. You should think of the entire assembly, including the Jeep frame. There's no point in making the bumper, winch mount and brush guard grossly stronger than the frame. At some level of disaster, something is going to get bent. Better it be something you've built and can rebuild than a Scrambler frame that's rare as hen's teeth. Of course it's impossible to design something that will give in the last instant before the frame does, but there's no point to building something that's three times as strong as what it's attached to.