front bumper mounting

Welder

No seriously, IIRC if you take the bumper off, there are bits where the "frame" rails stick out beyond the crossmember, two holes each. Isn't this what the factory bumper bolts to?
I made a bumper from a single $5 piece of scrap L-iron using those.
 
Bolt to the frame, weld to bolted pieces. You want to be able to remove it, right?
 
On my ZJ, my new bumper goes in to the unibody holes in the front and then bolts to them. I would not weld because then taking it off is a whole new problem. Use grade 8 bolts and you will be fine.
 
There's not really any reason to weld to the unibody. I've built quite a few xj bumpers and I always just make the brackets run down the side of the "frame" and tie them in further back as well as at the front where the factory bumper bolts. Most of the one's I built have winches on them and I haven't had a complaint yet. The unibody on an xj flexes pretty good in the front from the coil buckets and welding 3/16" or 1/4" plate to the thin sheet metal over time will just stress crack. Not fun at 65 mph on the highway when it falls off.
 
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