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The original prototype bumper was made entirely out of 1/8" plate with the mounts being 3/16", and I never got to actually weight the bumper correctly, so I guessed it to be around 65lbs. Ted and I took the bumper off the other day and I put it on the scale. Weighed in at 52 lbs. I was planning with the production model bumpers to go 3/16" plate for strength, but it would also take the weight up the bumper up to around 80lbs. If anyone personally knows Ted and I and how we trail test these bumpers, they get beat up real good. This last year Ted did some things to that prototype bumper that would make you cringe, and even though it was made of 1/8", it held up extremely well. After taking it off the other day and doing a full inspection of the trail damage, I have decided that with some slight changes and gussetting, the 1/8" plate will be quite sufficient for this bumper. The gussetting will reinforce the bottom of the bumper (center section under the hitch) that was the most vulnerable and received the only damage from all of Ted's abuse. By doing this, I can keep the bumper strong enough, and keep the weight under 65lbs. This will keep the jeep from sagging, and will lower shipping costs. The ARB bumper is mostly 1/8" plate with some doubling of material at the winch mount. I haven't done a real thorough inspection of the ARB, but the body of the bumper itself is 1/8" plate. Using 1/8" for the front bumper makes it light weight, strong enough for the trail abuse most people will inflict, but does not make the bumper indestructable, so if you get in an accident, you don't end up with a totalled jeep and a perfectly undamaged bumper. Oh, and the lighter material is also cheaper. I got a new cost sheet on all of my products from my manufacturer, and shop rate and material costs went up 15%, so using 3/16" material would put the cost of the bumper comparable to the ARB, and that would be too much for a non winch bumper. The only part of the bumper not 1/8" plate will be the mounts, which will be 1/4" plate, and of course the shackle tabs are 3/4" thick.
Anyways, a lot more info that asked, but that is what has been going on with my front bumper recently. In short, my front bumper will weigh in under 65 lbs with the current plan.
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