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Off-Road Bumpers: What to Know Before You Buy

1994 Mitsubishi Delica Space Gear after phase 1 upgrade front three-quarter shot(Photo/Mercedes Lilienthal)
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There are a few different features and factors to consider before buying an aftermarket off-road bumper for your 4×4. Our bumper basics guide will help you determine what type is best for your adventure rig.

From one-piece bolt-on affairs to customizable weld-together kits, off-road bumpers range in price, durability, and features. Are they painted or powder coated? Do they come with opportunities to integrate auxiliary lighting or add a winch? How many recovery points are there? Will those be enough to assist recovery efforts with the type of terrain you plan on tackling?

These questions are important to consider as you start shopping for a new bumper. Understanding the differences between bumper types and features will help you make the right decision when upgrading your off-road vehicle.

Off-Road Bumper Options: One-Piece, Modular, or Weld-Together Kit

Coastal Offroad Mitsubishi L400 Delica front bumper
Do you love the Delica as much as we do?; (photo/Mercedes Lilienthal)

One-Piece Pre-Fabricated Bumpers

The majority of aftermarket off-road bumpers sold on the market today are one-piece, pre-fabricated bolt-ons. From front winch bumpers without bull bars to rear bumpers housing various swing-away tire carriers, the selection is vast, with many price points to choose from.

One-piece bumpers are usually easy to install, super sturdy, and don’t have any additional parts that might come loose over time.

Warrior Products 3530 Front Winch Bumper
Warrior Products 3530 Front Winch Bumper; (photo/Warrior Products)

Warrior Products makes a variety of different one-piece bolt-on bumpers, including an FJ Cruiser front winch bumper. This unit will fit the most popular winches in the 8,000-10,000-pound capacity range that have removable control packs. The heavy-duty steel bumper weighs 94 pounds, has a full bull bar covering the 4×4’s grille and headlights, and recovery points on either side of the winch housing.

ARB-3423140 Front Deluxe Bull Bar Winch Mount Bumper
ARB Deluxe Bull Bar Bumper; (photo/ARB)

Other popular manufacturers of one-piece bumpers are WARN Industries, Smittybilt, EAG, Iron Cross, Rugged Ridge, and Rampage Products. Choosing what’s right for you and your vehicle is half the fun. From pre-fabricated winch bumpers to rear bumpers that feature a swing-away tire and/or jerry can holder, you have many choices in this segment.

Modular Off-Road Bumpers

Another style is what some refer to as modular bumpers. These bumpers give buyers a variety of options, allowing customization with items like a bolt-on brush guard, extra light-mounting tabs, or adjustable bumper widths.

One example of modular bumpers is the Rugged Ridge XHD Modular Front Jeep Bumper kit. This product has several configurable variations allowing you to create something just for you.

From different grille guards and recovery points to full-width or “stubby” configurations for better off-road performance, modulars let you choose the bumper setup you want.

ARB Chevrolet 3500HD Deluxe front bumper
ARB Deluxe front bumper; (photo/ARB)

Another option is the ARB Modular Bumpers for full-size trucks which are also configurable. Available in three versions, you can find a part number for each version and order a complete modular winch bumper solution to fit your truck.

This includes ARB’s Base modular (bumper only). The Sahara includes the base bumper plus the Sahara grille guard. The Full Deluxe modular bumper takes all that and adds the side “wings” to guard the headlights, giving you the most protection.

WARN trans4mer bracket kit for 2019 Chevrolet Silverado
WARN Trans4mer bracket kit; (photo/WARN)

Another style is the WARN Trans4mer mounting system. This setup maintains a truck’s factory bumper yet allows you to add a winch, grille guards, front receiver hitches, and other accessories designed for the system.

There are three generations available depending on your vehicle’s year, make, and model. All require a base Trans4mer winch mount, such as the Trans4mer Gen II for the 2019-2020 Chevrolet Silverado 1500 shown above. The other bits and pieces are bolted onto this base mount.

This isn’t a full bumper replacement, but rather a simple way to add a winch and various other versatile front-end accessories to your existing bumper.

Weld-Together Bumper Kits

Weld-together or DIY kits can be an alternative for skilled welders or home mechanics who want to take on a challenge. Some shops may do the work to fabricate these bumpers too.

Flat-packed and ready-to-ship, weld-together kits can be CNC-laser cut out of thick steel or aluminum and are ready to assemble upon receipt.

Coastal Offroad Mitsubishi L400 Delica front bumper tacked together on vehicle
Coastal Offroad weld-together bumper; (photo/Mercedes Lilienthal)

Although weld-together bumper kits may be less expensive than their pre-welded counterparts, keep in mind the additional labor costs and time to finish them. Buyers of weld-together kits may choose to do the work themselves or hire a fabrication shop to do the work, as I did with our Coastal Offroad van bumpers.

Coastal Offroad Mitsubishi L400 Delica rear bumper swingarm being assembled on vehicle
Rear Coastal Offroad weld-together bumper being assembled; (photo/Mercedes Lilienthal)

Note that if you plan to have a weld-together bumper kit powder coated or painted, expect to add that price to the overall cost. Some choose to paint their kits themselves to stave off further labor costs.

Weld-together off-road bumpers offer some pros and cons when compared to pre-assembled bumpers.

On the plus side, they can sometimes be customized before they are finished. You can alter the kit’s features if you don’t like them or add new ones if you have the resources and know-how.

On the other hand, if not welded together properly, these DIY bumpers could be a point of weakness during vehicle recovery or usage. They may also be more prone to corrosion or premature rusting if not painted or coated thoroughly.

Off-Road Bumper Finishes

Warn Industries AEV Brute custom Nemesis rear bumper on Jeep on trail
(Photo/Mercedes Lilienthal)

There are two main types of finishes for aftermarket off-road bumpers: powder coated or painted. Powder-coated finishes are more durable and come in a variety of textures. Powder coating can withstand scratching and chipping better than paint, making it ideal in salty environments where blemishes can lead to rust.

bumper getting powder coated at Precision Powder Coating
(Photo/Precision Powder Coating)

Powder-coated bumpers are typically sandblasted first, then coated with a specific textured or wrinkle powder before getting sent to an oven to “bake on,” hardening the powder against the bumper’s surface. A few manufacturers will add an extra step to powder coating bumpers: priming them. This adds an extra layer of protection against rust or other trail hazards you may encounter down the road.

Unfortunately, one downside to powder coating is you can’t re-coat damaged areas with more powder coat. They’ll have to be touched up with paint instead.

Painted bumpers, on the other hand, are typically found on less expensive aftermarket off-road bumper options. Painted bumpers, while not as long-lasting as their powder-coated cousins, are easier to touch up when damaged.

Off-Road Bumper Accessories & Add-Ons

Aftermarket bumpers offer a variety of different accessory options to suit buyers’ needs. This includes winch mounting plates, allowances for recovery accessories (such as shackles), jerry can holders, and accommodations to mount auxiliary lighting.

Mitsubishi Pajero ARB one piece front bumper
(Photo/Mercedes Lilienthal)

Front and rear bumpers typically have voids placed within them to house things like high-powered cube lights (no matter if they’re floods or spots or something in-between). Front bumpers often have room for top-mounted auxiliary driving lights with pre-drilled holes ready for mounting.

Winch mounting plates are another common commodity found on off-road bumpers. However, consumers need to measure the area correctly. Or contact the bumper manufacturer for dimensions before purchasing a winch to ensure the winch will fit.

JCR Cherokee rear bumper swing arm on vehicle climbing sand dune
(Photo/Mercedes Lilienthal)

Off-Road Bumper Bounty

No matter your budget or desires for an adventure-ready off-road bumper, chances are you’ll find exactly what you’re looking for. With a multitude of one-piece, modular, or weld-together kits available, you’ll be praising your latest upgrade in no time.

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