What about bringing the bumper up until that gap is filled...then notch out the bumper that covers the grill and turn that piece over and weld it in place? Since your electrical connection blocks part of the grill anyway, go to an intergrated winch that does not have a separate box and sacrafice just a bit of grill opening for the small section of grill that would be covered by the winch. Then go to a rope and rope fairlead so the overhang is much smaller and the set up would be about 35# lighter. If you have to, build a separate "guard" for the windshield fluid tank.

We don't want "NO MORE PLASTIC"

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Founder of L.O.S.T.
2006 CRD Sport
Mods: GDE Hot Tune w/ 364#@2000rpm/Air Box /3" Str8 Exhaust/ASFIR Alum Skids/245-75R-16 Cooper STT PRO/OME LIFT w/Clevis & 4 Spring Isos/AirTabs/Rigid 10" S2 LED/4xGuard Ctr Matrix Bumper
Drag Strip:Reac=.1078_60ft=2.224_1/8=10.39@64.8mph_1/4+16.46@80.8mph

The way I am picturing that in my mind it would be pretty cool and cut the overall cross section down which I think would make it look better. That would allow the 2x8 material to work the way I had envisioned the 2x6 working and address filling in under the turn signal.

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99 TJ
71 C101
04 KJ
03 SFA KJ Sport
LOST JEEPS So-Cal

Yep, it would still be full size on the ends and shorter in the middle...but the bottom would be the same all the way across. Approach angle would be much better since the whole bumper would move up the distance to the bottom of the turn signals. Would also give it some asthetic "depth" IMHO

I guess you really couldn't weld the piece that was cut out in place without trimming off the the sides but you get the idea...just weld the long flat stock back to fill in the gap created by the notch. Then two small pieces to fill the vertical gap.

_________________
Founder of L.O.S.T.
2006 CRD Sport
Mods: GDE Hot Tune w/ 364#@2000rpm/Air Box /3" Str8 Exhaust/ASFIR Alum Skids/245-75R-16 Cooper STT PRO/OME LIFT w/Clevis & 4 Spring Isos/AirTabs/Rigid 10" S2 LED/4xGuard Ctr Matrix Bumper
Drag Strip:Reac=.1078_60ft=2.224_1/8=10.39@64.8mph_1/4+16.46@80.8mph

That all sounds good in theory, but I bet if you did what you said it would look odd, I followed the frame angles and spaced everything about 1" off the unibody frame.



Darby is right about bringing the bumper up to close the gap, I would have had it right the first time if it weren't for my slightly askew eye-ball technique. The next one will be snug up against the grill and the winch will be raised 3.5" and tucked up more to the grill; this will be done by making the winch plate shorter. I am also working on a turn signal housing out of my old bumper with a wire mesh "intake" to fill a small gap, for looks only

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Black '06 CRD: 2.5" OME lift, Aero Turbine Exhaust, Warn m8000 on custom bumper. NEW Falken Ziex S/TZ04 245/75/16's Scored a smokin' deal @ http://www.tirezoneusa.com

OD '48 Willys CJ2a: fresh motor, new wiring harness, stainless exhaust, bestop, 34" TSLs and about 200 hours into the thing, possibly FOR SALE

Here are some crappy pics I snapped today...

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Black '06 CRD: 2.5" OME lift, Aero Turbine Exhaust, Warn m8000 on custom bumper. NEW Falken Ziex S/TZ04 245/75/16's Scored a smokin' deal @ http://www.tirezoneusa.com

OD '48 Willys CJ2a: fresh motor, new wiring harness, stainless exhaust, bestop, 34" TSLs and about 200 hours into the thing, possibly FOR SALE

I think it need a few angles on the bottom side of the bumper to make it look more agressive. Right now it looks a little bland.

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2005 CRD , Moab Rims, 245/75/16 Goodyear M/T
RL rear bumper, TMJ Front bumper, Frankenlinft,
*TOTALED*

1985 Mitsubishi Pickup SP 2.3 Turbo Diesel Watercooled turbo,4D56 ported head,
12" Suspension Lift with JK Rubicon axles, Elockers, 5.13's, Fox coilovers, Atlas 5.0, Rock Lizard supersliders

1996 Lexus LX450 -locked and lifted-