I’m curious to hear about others who are running aluminum winch bumpers and how they are holding up. I’ve had my Pelfreybilt aluminum bumper mounted for just about 3.5 years now. It has survived a decent amount of rock strikes and probably a couple hundred winch cycles during that time. Recently I noticed some cracking near the frame horn mounts so I think it’s days are numbered. Not sure if it’s a poor bumper design or just the reality of using aluminum for a front bumper that gets used.

How are your aluminum bumpers holding up?




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Bump, because I wanna know as well. I was running aluminum skids and ended up switching some of them (like the engine skid) to steel for better performance according to my use.

Now I'm planning on front/rear bumpers and looking to decide whether to go with steel or aluminum again.

Old post I know but I'm going to be heading in the winch bumper direction soon and found this searching for aluminum bumper threads on here.
My biggest issue is Maine winter roads. The salt and brine are hell on everything and had the thought that aluminum might be a good option that won't rust.
If there's a design issue with some though it would be good to know, and if they simply can't withstand moderate use it would also be good info to be armed with before dropping a lot more money. I can factor in rust maintainence to the equation if I have to for cost of steel vs Al.
Thanks.

yes they will withstand moderate use and hits. However, if your idea of moderate use is rock crawling where you are planning to take hits to your bumper everytime you take it out on the trail then you might want to stick with steel.

Understood.
Thank you.

I love aluminum, its light and doesnt really rust. That said like above it wont take the hits. I have mixed skids half steel half aluminum. Some here have said basically with aluminum its a temp plate to take a few hits then get replaced.

Maybe we ought to get the vendors to make them out of 1 inch titanium... that should work if anybody wants to drill out the holes

The way a lot of people market Aluminum is shitty. Yes if you look at the strength to weight of something like 6061-T6 vs. mild Steel aluminum wins, but that is the raw material only. When you weld Aluminum you ruin that -T6 tempering that gives it all its strength in the heat affected zone. Mild steel does not have this issue, and with proper welding it is generally stronger at the weld joints due to the bead thickness adding to the cross sectional area.

My bumpers and skids are all steel, just answering your question about the reality of aluminum.

I’m a big fan of aluminum but you have to be cognizant of where you going to put it and what your vehicle uses are.

I'm okay with aluminum on the front as I'm not usually dropping off into a massive rock gardens with boulders that can hit the front bumper everywhere, however definitely need steel on the belly and booty.

Ive had a pelfreybilt front bumper on my rig for about 5 years now and love it for weight savings. Its taken a few hits on the lighter side. I never put a winch in it as Im trying to keep it light and rarely wheel hard enough to need one.

All my other armor is steel though. With all the times Ive been in tough spots I think Ive only really relied on my sliders a handful of times. Aluminum probably would have done the trick except it likely would have taken much more damage.

My biggest fear w/ aluminum is doing a recovery and having a failure like in this photo. See IG link for more pics (not my rig). Pretty rough and Im sure the repair was a nightmare. Flexural Rupture at the frame connection I believe.

https://www.instagram.com/p/CPJGqlOn...3D&img_index=4

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Lol titanium. I have dreamt many a dreams about titanium.

Awesome folks. Really appreciate the guidance/input with this. Exactly what I was looking for.

OP back for an update. Ditched the Pelfreybilt for a CBI aluminum full front. Had it for just about 2 years and have hammered it across a lot of the really technical trails we have out west. Including most recently a tour through the Rubicon. At least 100 winch cycles in with plenty of rock strikes and it’s still going on strong.

Also on the whole debate around aluminum skids not being up to the task of rock crawling. I’m prepared to debate that heavily. Mine are just fine after years of abuse and the only real negative I see is that aluminum doesn’t slide as easy as steel. Acceptable for me given the weight savings.




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To me it seems hard to justify spending $600 more for armor that's not as strong that'll only save 100 lbs if I do the math on the 3 skids and a front bumper.

I don't know what the mpg benefit of saving 100lbs is, but if its half of a mpg then you save $30/yr if you daily the truck. Meaning it'll pay off in 20 years.

Obviously it depends on which bumpers you're using as examples but the weight savings on a front bumper alone is 100#, for the skids add another 80-100#. I think the 100# in the front makes the biggest difference personally. Don't have to run as stiff a coil.
I'll have to agree with @Xtremluck . I've had my aluminum front bumper and skids for 8 years and they've done very well through some pretty good abuse. It does matter who you buy from and how they're built same as it does with steel.

As far as sliders and rear bumper goes I'm in 100% agreement, steel is the way to go.


*added note: There's not a single thing on my rig that was a good investment or will justify it's expense at any point in time. It's all purely for my own joy.