Next I had to design a frame mount that would firmly hold the brush guard to the front frame and also provide the additional 1/2 inch of width I needed to attach the brush guard to. Since the brush guard verticals were 29" wide outside to outside measurement and the frame was 29.5 inches inside, I opted for 1/4 inch plate steel to construct the frame mounts. I made the templates out of card board again and started experimenting with different shapes that would provide adequate support. Once I had the template shape completed for one side, the template was interchangeable with the other side EXCEPT for the fact that the driver side had the factory steel recovery loop welded to the frame so I had to cut a relief in the driver side tab to clear the recovery point. I thought I had the shape nailed down, then it occurred to me that once I had the plate welded into shape, I could not maneuver the brackets over some of the frame obstacles... so I began reducing the bulk of the frame mounts with some major cuts then some fine refining on the grinder. I built a wooden template of the Tracker frame where the mount would rest (2 - 1/16th inch wide) with the bevel included and clamped the plate parts together, tacked them together, then trial fitted them again. I added a gusset to the lower part to reinforce the mounting tab. 1/4 inch plate is probably over kill, but i had access to a machine shop band saw which made the cuts quicker and more accurate. When they fit I beveled the edges on all the plate edges and ran them over to my local welder who laid some great bead on them.
For final assembly I have to remove the plastic bumper cover off Buster, paint the mounts and frame area with Herculiner, then tap holes through the brackets and frame assemblies (one in the front and one in the rear) then add an inverted "U" shaped 1 inch steel strap (12 inches long) over the top of the frame (tap holes to accept the front bracket mount bolts) to provide more vertical support to the mount. Then put the plastic bumper cover back on, align the brush guard evenly with the grill and headlights, clamp and mark the holes on the brush guard to the tabs on the fabricated frame mounts, remove the plastic cover once more, tap the mounting holes, reassemble and bolt the brush guard onto the mounting tabs. I hope to get the final assembly done this week.