Nates4x4.com: Nates4x4 designs Suzuki Samurai Front Winch Bumper

Nates4x4 has been designing Jeep Bumpers for years. But recently, due to a dwindling economy, we have also taken interest in expanding our production line and catering to other popular offroad vehicles. When Ryan B. came to us with his 1992 Suzuki Samurai in need of sturdy and reliable recovery points, we welcomed the project. With eight years experience in off-road body armor, we were confident that a bumper system could be designed quickly and efficiently.

However, each new prototype vehicle that comes into the shop presents its own challenges that must be overcome to produce a quality product. After doing some research online, we were astounded to find that many manufacturers were utilizing only four (weak) mounting points for their front bumpers, while offering such options as winch plates and recovery points. We were determined to design a superior mounting system that would set the product off from our competitors.

Upon meeting Ryan, he showed great interest in our "Model 2" Wrangler Winch bumper, designed to be a universal fit for 1976-2006 Jeep CJ, YJ, TJ, and LJ. On these models, the bumper is easily installed by setting it on top of the frame rails, and installing bolts into the threaded factory holes in the frame rails. The Samurai is set up a little different. The frame rails do not extend past the grille of the vehicle, making this mounting system impossible. The bumper must be mounted to the sides of the frame rails. Further complicating this, Suzuki Samurais have a unique crossmember welded not only between the frame rails, but also extending to the area outside of the frame rails. The crossmember is relatively thin ROUND tubing, and measures just shy of two inches O.D.

Since all the products Nates4x4 sells are designed to be direct bolt-on with minimal modifications to the vehicles, we had to get creative. We combated the in-the-way crossmember by developing a two-piece forked mounting bracket. The first part of the bracket bolts securely to the frame rail utilizing five mounting bolts per side. While the passenger side does require drilling three holes, the drivers side bracket is securely sandwhiched between the steering gearbox and the inner frame rail, utilizing the same pre-existing holes as the gearbox. The forked ends spread around the crossmember, offering larger diameter holes, through thicker plate steel, than factory mounting locations.

The second part of the mounting bracket was integrated into the bumper itself. We designed a bracket that fit snugly inside the back of the Model 2 Winch Bumper. In addition to part of the mounting system, this bracket also acts as a gusset, giving the bumper extra strength. The bracket extends from the bumper to line up with our new, improved mounting points, as well as hitting the factory mounting locations. The front bumper is now held on with eight hardened bolts. The D-Ring tabs are now safe for tugging, and the winch plate safe for any recovery operation.