Novak Conversions Jeep Wrangler TJ engine mounts

Tool to Radius Bumper Winch Point

JMT

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What tool would one use to radius a winch point hole on a rear bumper? There’s not much standoff from the bumper. I’d think some kind of routing bit, but on a drill rather than a router, but don’t know what I don’t know.
 
What tool would one use to radius a winch point hole on a rear bumper? There’s not much standoff from the bumper. I’d think some kind of routing bit, but on a drill rather than a router, but don’t know what I don’t know.

People have used the flapper type sanding discs before. I can't remember when or where it was discussed.

I think like this?

1751674431704.png


https://www.amazon.com/TOKIDNY-Abrasive-Sanding-Electric-Grinders/dp/B0DGYM76Y6?tag=wranglerorg-20

Or like this?

1751674514830.png


https://www.rosver.com/en/product/conical-flap-wheels/
 
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I guess I could use a step bit and then a flapper style like you mentioned @Wildman and get it nice and smooth. Thanks!
 
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I guess I could use a step bit and then a flapper style like you mentioned @Wildman and get it nice and smooth. Thanks!

Jeremy,
I think people talked about making their own using strips of sandpaper but I don't remember what they were attaching the sandpaper with. I tried to radius my bumpers but don't really think I did them enough.
 
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Ok, that didn’t work. Started with a die grinder and that took the edges off.

IIRC, the main thing is taking the edges off. I need some correction or corrective on that point someone knows
 
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What tool would one use to radius a winch point hole on a rear bumper? There’s not much standoff from the bumper. I’d think some kind of routing bit, but on a drill rather than a router, but don’t know what I don’t know.

I used a die grinder with a carbide burr. All you care about is where the soft shackle can be pulled against.
20250503_120907.jpg

20250503_122841.jpg
 
Ok, that didn’t work. Started with a die grinder and that took the edges off.

IIRC, the main thing is taking the edges off. I need some correction or corrective on that point someone knows

I got the discs like the second one I posted and used that. But I'd also take the edge off before I'd welded up my rear bumper. The front I just did as much as I could reach. I got mine at my local ACE Hardware
 
Here's how I did mine.

20250704_182655.jpg


20250704_182700.jpg


I looked and just realized I'd never done the front bumper.
 
I have one of these carbide burrs for putting a 1/8" radius on things with a die grinder in my burr drawer:
https://us.pferd.com/en/high-performance-tungsten-carbide-burs-edge-cut-conical-counterbore-18-radius?a[diam-outer-inch-tds]=5/8+Inch&a[length-construction-inch-usa-tds]=5/16+Inch&a[pferd-type-tds]=V+1612/6,35+EDGE+R3.0+ECS

Not cheap, but it does a nice job. Here's one that's not in my burr drawer, but I'd like to add it. Only seen one once, and I'm not sure where to buy one:
https://www.premiumtool.com/convex-concave-carbide-burrs/

I use the crap out of the 1/2 inch mini belt sander.
 
Sandpaper roll will be good for polishing after it’s radiused, but it would take forever to radius with it. The steel burrs would do the cutting well.

I prefer to use rated D link shackles and leave them in place. That makes for a radius that will confidently not damage the soft shackles. Mine were expensive, but I feel good about them. I have no steel components my bag. I did carry a steel snatch block until I used a soft shackle and thimble ring a few times and gained confidence in them. I then ditched the steel snatch block and probably saved twenty pounds.
 
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Sandpaper roll will be good for polishing after it’s radiused, but it would take forever to radius with it. The steel burrs would do the cutting well.

I prefer to use rated D link shackles and leave them in place. That makes for a radius that will confidently not damage the soft shackles. Mine were expensive, but I feel good about them. I have no steel components my bag. I did carry a steel snatch block until I used a soft shackle and thimble ring a few times and gained confidence in them. I then ditched the steel snatch block and probably saved twenty pounds.

If you are using steel shackles, you do not need soft shackles. In the interest of safety, you ought to eliminate one or the other to reduce the amount of connections in the rigging. In the further interest of safety, your rigging ought to be light weight where the opinion is available. A soft shackle is lighter than a steel shackle.
 
Novak Conversions Jeep Wrangler TJ engine mounts