Front Bumper, Welding, Winch, etc....

[XRACER]

So I have some new bumpers for the 2003, and I'm considering a hydraulic winch for the front. The original bumper seems to be mounted to a bracket, which seems to be bolted to the frame. It may be spot welded too, but I haven't gotten a good look yet. So my questions are these:

1. What is the shear strength of the bolts that hold the brackets on?
2. Should I weld the brackets to the frame?
3. What is the procedure for protecting the truck prior to welding?
4. What sort of flow and pressure can I expect from the stock power steering pump, and are there after-market options?

Thanks for any help........

[Clark2]

I can answer #3
1) Everyone agrees that you should completely disconnect both batteries.
2) Not everyone agrees but I also disconnected the PCM and the IDM

[SuperbeastVan]

Originally Posted by Clark2

I can answer #3
1) Everyone agrees that you should completely disconnect both batteries.
2) Not everyone agrees but I also disconnected the PCM and the IDM

Can you elaborate on this? I've done hours of welding on my van and never done this.

[SuperbeastVan]

1) Not sure, but you could always upgrade to grade 8's. They are fairly large bolts. If your 2003 is like my 2000, it really isn't a shear force. The way mine bolts, it would be a pulling force. My mounts are welded to the frame.

2) Welding is almost always stronger than bolting, as long as it is welded properly.

3) Cover burnables as best you can with sheet metal or even tin foil before welding.

4) Not really sure of pressures, but I don't believe it is enough to power a hydrolic winch if that is what you are thining.

Just a note to think of. If you are leaning away from an electric winch and you get stuck in deep water and stall the engine you will not be able to use your winch.

[Clark2]

Disconnecting the batteries is pretty widely done. It has to do with the batteries being grounded to the frame or something like that. I've read of people welding without disconnecting with no problems, but it is a risk. In regards to the computers - it is required by the Ford Manual and I did it since it only takes a couple minutes and the modules are expensive.

[XRACER]

With the AIC keeping the engine at 1100 rpm (and the emergency brake engaged 'switch' thrown) I'm hoping that one of these will work.....Hydraulic Recovery Winches

Still just wondering on a flow and psi specs on the PS pump. I'm not really concerned with the need to run the engine. A powerfull electric winch will leave you stuck AND with a dead battery if you don't keep the engine running.

As for the bolts, the bumper is held on to the mounting bracket by bolts in tension. The bracket is held on to the frame rails by bolts in shear. I guess I could just weld up the whole thing.....

[blageurt]

Bolt it together with grade 8 's and weld the seams where the brackets meet the frame as a safety. That way if they move at all you will see it the paint flake or come off the welds . Bolting should be fine with proper ones , use a factor of safety for bolt Shear Stress of 5 ( where .7854 x diameter squared would be bolt area in inches ) and Max Shear Stress in PSI.

[Clark2]

I didn't realize that warn also makes hydraulic winches. I'd only seen the ones from milemarker. They were only about $600, but they aren't warn.

[XRACER]

OK, I found the shear and tension info. In case you need to know....a 1/2" grade 8 will fail at about 30,000 lbs in tension and 17,000 lbs in shear.

I'd still like to find the power steering pump specs, but I'm having trouble.

Anyone?

[SVONick]

Here is what I found on AllData for an 03 E350 PSD:

Pressure 1,034 kPa (150 psi) Fluid @ 74°- 80°C (165°- 175°F) Engine at 1,500 rpm

Relief pressure 15,200 and 18,000 GVWR 9,000 - 9,900 kPa (1,300 - 1,430 psi)

Relief pressure 20,500 17,000 kPa (2,465 psi)