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Enjoying the picture story as always.
Any idea how much net weight this bumper adds after taking off the stock pieces?
May want to keep an eye on where the winch control box meets the grill. With one being attached to the frame, and the other on the body, they'll flex and may contact. Shouldn't be as much displacement as at the fenders, and the grill should flex without issue. Looks great!
Glad to hear it! It's very difficult to get accurate weights on everything without physically weighing the individual pieces, but the shipping weight for the Rhino bumper is ~130 pounds. That includes a TON of heavy packaging and a few parts you don't need, and I would say the actual bumper along with the mounting hardware is probably 100-110 pounds. The shipping weight for the ARB and TJM bumpers (from googling) is around 250 pounds, but I'll bet the actual bumpers themselves are around 180-220 pounds. The Warn winch shipping weight is 72 pounds, so I'll bet the mounted weight is around 65 pounds. Removing the stock bumper, the aluminum crash bar and related hardware is probably about 25-30 pounds, so if I had to guess, I would say I added about 150 pounds to the front end. From my back of the envelope calculations, I think I added a net of about 150 pounds to the front of the vehicle, so I think I "saved" about 70-110 pounds going this route over the ARB or TJM. I think the 2702 front springs are basically perfect for this setup because it doesn't feel harsh at all whereas with the stock front it was quite stiff.
Regarding the winch/grill interface, I was definitely concerned about the body and frame flexing independently and causing issues, but I have tested it in the field and feel pretty good it isn't a concern. I finished the front end on a Saturday night, and Sunday morning we left on an 8 day trip that included dune bashing at 35+ mph, 60+ miles of the Alpine Loop in mixed terrain, some sections of rock crawling, and more dune bashing on the way home. Then I went to LCDC for a day and ran a trail that included some mild rock crawling where I kissed a rock with the front bumper, and the grill never moved, squeaked, or made any noise at all. I was definitely ready to trim the grill for clearance, but I don't think it will be necessary. The only plastic trimming required on this front bumper for me was just the fender liners, and I found my wife's fancy sharp garden shears worked about 100x better than anything I've used in the past to trim the thick plastic fender liners.