Adding A Winch Capable, Full-Width Steel Tube Bumper

After owning my Bronco for three years, I’ve concluded that I’m still in love with this vehicle. I sometimes wake up in the morning and stare at it longingly like I did my first wife in our first year. But unlike my first wife, this love stands the test of time.

When I stare, I admire her figure and wonder what modifications suit my lifestyle best. While I’m not pining to conquer the Rubicon, I don’t mind looking as if I could. My main goal with the vehicle is to confidently get off the beaten path to enjoy existing in nature, e.g., camping, paddle boarding, or cooking outside. In a broad sense, overlanding.

I enjoy moderate wheeling with other humans but covet solitude and like to explore independently. After getting stuck on my first solo snow excursion and my recovery gear consisting of a $14 hand shovel (5 hours later), it was evident that I needed a winch.

After coming to grips with this reality, I searched for a solution. The front bumper options a few years after the release of the 6th Gen Bronco were vast. I wanted something fairly lightweight, sturdy, looked good, and, most notably, winch-capable. I also didn’t want the winch to stick out 10 feet. That narrowed down my options considerably.

Enter Baja Forged. I discovered them from a SEMA Bronco build. They are a female-owned company in SoCal. I was instantly attracted to the Baja-style bumper that paid homage to the vehicle’s race heritage, and it had the most tucked winch installation I’ve seen.

Find It Online

• Baja Forged Crawler Bumper: Check Price

Features & Specs

• Contoured design integrates seamlessly with factory body lines
• Decades of off-road and BAJA experience influence the design
• Includes push bar and D-rings
• High-clearance design (up to 48 degree approach angle)
• Constructed from mandrel-bent, high-strength steel tubing and heavy-duty steel plate
• Heavy-duty steel mounting plates use factory mounting points for secure installation
• Compound rolls and bends provide a robust, sophisticated structure
• Tow-ready D-rings compatible with adjustable tow bar
• Aggressive front stance
• Integrated skid plate mounting tabs allow easy maintenance
• Light mounting plate reinforcement supports multiple lighting setups
• Made and designed in the USA
• Tested in extreme terrain of Johnson Valley, California (King of the Hammers)
• Additional customization options available for personal setup
• Solid blend of capability, style, and durability

Installation

Installation is pretty straightforward and requires minimal tools. Everything is bolt-on, so no welding is required.

Tools & Materials

• Clip Removers
• 15mm and 8mm Sockets
• Impact Gun – recommended
• Allen Key
• Rubber Mallet – recommended
• Masking Tape – recommended

Add Accessories (Optional)

If you are installing a winch or lighting, add them before mounting the bumper on the vehicle to ensure fitment. The bumper comes equipped with a mounting plate for these items. Put masking tape down and mark where you need to cut. Baja Forged recommends a professional for this step.

Step 1. Unplug Bumper Sensors

Note: I have the Badlands bumper option, so this removal may vary slightly if you have the plastic or modular version.

Park on a flat surface and use the included blanket as your work surface. If you have them with the Lux package, proceed to unplug the front bumper sensors from both sides. They are located behind both corners of the bumper.

I didn’t have them, but depending on your model, make sure any plugs routed to the bumper are unplugged.

Step 2. Remove Factory Skid Plate

To remove the (4) front skid plate bolts, use a 15 mm socket (or one appropriate for your model).

Step 3. Remove Factory Bumper

Next, remove the bumper caps using a clip puller or a flathead if you’re a barbarian. Then, use your socket to remove the (3) bolts on each side behind the bumper caps.

*Attention Non-SAS Broncos* If you are planning to upgrade to larger tires, now may be a good time to remove the crash bars like I did while there’s no bumper in the way.

Step 4. Remove Louvers

Using an 8mm Ratchet, remove the (4) bolts securing the louvers, (1) in each corner. If you have the Lux package, you will also need to unplug the Adaptive Cruise Control. However, relocating that sensor is its own process we won’t cover here.

If you are installing the Baja Forged skid plate (sold separately), as I did, remove the bracket that holds the intercooler. Make sure to do one side at a time, and replace the factory brackets with the L brackets provided with your new bumper.

Step 5. Mount Bumper

Tape off the lower section of the grill so as not to damage it when installing the new bumper. This job is best suited for two people. You can place the bumper on a floor jack for added support while you and a buddy line up the mounting points.

To mount the new bumper, you will use the factory bolts that were previously removed. Install all (6) bolts and tighten once the bumper is in place.

Step 6. Install Skid Plate (Optional)

Once the bumper is installed, you can install the new skid. If you have a differential skid, make sure to remove it, as it shares a mounting location with the new front skid. You will reinstall the differential skid after the new front plate is on.

The instructions say to use the clips provided and tap them in with a mallet, but I didn’t receive any clips. So, after my buddy left, I used a floor jack to support the base of the skid as I lined up the (4) bolts. Start with the top of the skid and make sure the washers are tight, though don’t fully tighten until you’ve got all the bolts in, as you may need some give to adjust its position. Then, you can move to the lower section.

Final Thoughts

Though Baja Forged’s instructions weren’t completely accurate, even a novice like me could figure them out. I initially thought I was missing parts, but it was later explained that their instructions needed to be updated to reflect new parts and remove obsolete ones.

The owners were incredibly responsive and seemed like great people. This bumper provides as tucked a winch as I could find. The look is elegant, and the welds are seamless. I absolutely love my Crawler bumper and would highly recommend it!