Custom Winch bumper for 09-13 Subaru Forester

Since 2018 when I bought my 2010 Forester, I have been modifying it into a capable offroad vehicle. Upgrades include the following:

Thule roof mount Aero crossbars
2″ ADF lift
Method MR502 racing wheels
BFG KO2 All-Terrain Tires
Rallitek 0.25″ Springs
Roof Top Tent
Slotted Disc brake Rotors
Torq Locker’s Rear DIFF Locker
All LED Headlights/Tail lights upgrade
ADF Ditch light mounts and POD lights
Tri-band HAM Radio

Though my forester never failed to come out of difficult situations, only thing I felt lacking was the confidence of a winch. Sadly, aftermarket winch bumpers which are nicer looking were costing $1300 and upwards without the winch! Since I have already worked on small metal projects, I thought of giving the winch bumper a try. This will be a hidden winch bumper. ie. The winch bumper will be hidden under the existing bumper cover with provisions for shackles and winch fairlead.

Disclaimer

This is not exactly a tutorial or professional guidance on building a winch bumper. This serves as just documentation for myself and an idea inspiring post for other Subaru enthusiasts looking to build a winch bumper. Replacing the stock bumper beam which absorbs impact from collision with a rigid winch bumper could lead to frame damage, serious injury or even death in case of accidents. Feel free to get inspired and build one at your own risk.

Tools and Materials

Angle Grinder and Drill
MIG Welder (Titanium 125 DC welder)
1/4 inch thick 2 inch steel tube (1.5ft approx)
1/4 Steel plates for mounting brackets
3/16 inch Steel plate
X-BULL 4500LB Synthetic winch
Clevis mounts
3/8 inch shackles
Rustoleum truck Bed-liner paint

Step 1:

I removed the bumper cover and the stock bumper beam from the car. I used 1/4 inch thick steel plates and tubes for shackle mounts.

Step 2:

Mocked up the 3/16″ winch plate for exact dimensions and cut them. I also cut the bumper cover at correct places for the shackle mounts to poke out. Started off with a small cut on the bumper cover, put it on the car and I cut more as required. I measured multiple times before I cut them to the shape I wanted.

Step 3:

Added gussets and supports under the winch plate for more strength. I might have gone overboard with it; but it is never wrong to be extra safe when it comes to winch bumper build.

Step 4:

Final Welding, painting and mounting the winch on the bumper. I was extremely happy with how it turned out to be: Super strong and super clean hidden winch bumper.