Never did say what the other project was I was working on when I rang my bell...
The grill guard that is on the front of my truck is actually mounted to the frame via "clamps". There is a piece of 1/4" steel placed across the top of the frame rail, then the mounting bracket (also made of 1/4" steel) is placed below the frame rail. Two long bolts then go through the bracket, up along each side of the frame rail to the steel placed across the top of the frame rail, basically clamping the bracket to the frame. It works, but isn't as secure as I'd like it to be. Particularly as I use the grill guard to mount the recovery hooks to. That said...
I went to the pick-a-part and got as many of those doubled up bolts that hold the rear bumpers on 2nd gen Explorers that I could get my hands on. Then last Saturday I removed the front bumper and really studied closely how the grill guard mounts work. I realized that I could drill holes through the mounting brackets (don't worry, I'll take pictures later) and on through the frame rail, and use those Bumper Bolts to bolt the brackets directly to the frame, going through the front of the boxed frame to place the bolts inside the frame. There would be two very large bolts holding each bracket in place, eliminating the ridiculous clamp setup. This is the task I was working on when my Drill Bit broke a week ago. I had one hole on each side completed so I bolted everything back together and called it good til I could replace the 5/8" drill bit with a better one. Then I get to start the project over, removing the bumper, the grill guard, etc. just to drill two more holes in each bracket. fun fun fun
Why go to all these lengths for the extra strength (and all these paragraphs to tell you about it)? I had another thought as I sat here cooling off after working in the back yard. I am doing all this so I can be confident in the recovery hooks I am installing. If I am that confident in the increased strength, couldn't I have a mounting bracket for a winch made that would mount to the 1/4" steel grill guard mounting brackets? The winch would mount between the grill guard plates, right in front of the bumper, below the grill and above the air vents in the bumper..... thoughts?
Those big bumper bolts have come in handy for a number of things. I used several to mount my receiver hitch. Just cut the steel strap joining them together and I have a bolt that doesn't require two wrenches to install the receiver. (with the set up now I remove the receiver when I'm going anywhere I suspect I'll need the extra clearance.)