After checking out the guys' rigs who met up last Saturday for the 4x4 Expo I changed my mind about using the stock rear bumper. I had originally wanted to build one, but got lazy.
The idea is not to build an anchor point for recovery, but just more of a space filler and a step for loading the roof that will be as tucked as possible to avoid hanging up on terrain. The stock center loop and the frame-mounted D-ring mounts I'll add will work for recovery points.
I decided to use the piece of 2"x4" thick-wall tube I had in my scrap bin. I started by figuring out points to cut, pinch and weld to get it to sort of mimic the curve of the rear of the Montero. Once it was close enough I had to figure out what to do at the corners to bring it forward to the rear of the quarter panels. I decided on using a piece of round tube for a smoother look. This was just tacked. It will get fully welded and the strength will come from a full-length piece of plate that will make the top surface of the bumper. It will go forward and follow the body to make a flat surface and make the bumper look beefier.
Then I cut out the bottom center so it would clear the recovery loop. I was able to utilize the bumper mounts I'd made to raise the stock bumper. I bolted them in place, made sure the bumper was where I wanted it and welded them up.
Another day and it should be done. The bummer is that my travel season starts in a couple weeks, so I have to hurry before I'm on the road for work.
The angle turned out to be too much so I cut the tacks and used washers as shims so it wouldn't close as much.
With just the first two center cuts.
I added two more cuts to each end to get the "curve" and started on the corners.
I will be trimming the quarter panel to follow the bottom of the bumper.
At first the opening above the bumper corner bothered me, but the more I think about it I think it will make a good step for loading the roof when it gets the plate surface.
Trimmed around the stock tow loop.
Raising the gas tank may be the next project.
The bottom of the mounts will get trimmed off. The frame horn will get trimmed and I will mount hefty d-ring mounts inside (like I did on the front).
Temporary support for the corners.