Brody
September 8th, 2009, 07:15 AM
Andrew got in touch with Sean and me for a winch install. Since Sean went fishing, I did the install yesterday.
Andrew wanted to get a full bumper with a winch, but, like most of us these days, funds were short, so we agreed to do the winch first, then do the bumper later on. This posed a couple of problems as I had to mount the winch plate in such a manner as to have it both functional and removable for the final bumper installation. Generally, the winch plate would be mounted permanently with only the winch itself being removable (the way I would mount it anyway). In this case, I wanted to bury the winch in the frame rails behind the existing stock bumper. When the new bumper is designed, the winch will be moved to the top and we will lose some of the frame to improve approach angles. I used a piece of 2x4x3/16for a frame stiffener and back mount for the winch. This I welded in place and bolted the backside of the mount to it. I also used some 2x2x3/16 angle for the font mounts that were also welded to the frame and bolted through the mounting plate. I welded the plate to the frame with two stitch welds to the back of the plate on the bottom side as additional reinforcement. These can easily be ground off when the new bumper is built.
He got a very nice 10.5K Superwinch and we used a universal mounting plate from MileMarker that was 36" long. This was actually a pretty good deal at $70 and is certainly stout enough. Being a 'universal' mounting plate, there were some modifications needed, but they were minor. I had to notch for the frame rails, then drill out the fairlead holes so that I could use the 1/2" bolts I wanted to use. I also need to drill out some of the existing 3/8" to 1/2" for the same reason for the frame mounts.
I located the winch on the mounting plate, put it on a floor jack and and started measuring to see what and where I needed to cut. Rather than trim the plate, I cut off the inside of the lower bumper mounts so that the winch and plate could slide forward enough to get the fairlead to the front of the lower bumper. Then I trimmed the inside of the lower bumper and cut out the outside to expose the fairlead. This worked well and managed to move the clutch lever far enough forward to clear the radiator mount.
I then cut and drilled a piece of 2x4 steel for the rear mount of the winch, which I bolted the back of the plate to. This piece was welded in and will act as reinforcing for the front of the frame rails. The sides of the winch plate were bolted to steel angles that are welded to the inside of the frame rails.
I notched the front top of the bumper to ease access to the clutch so that you can use it easily with the hood down once the remote is in place. Then I cleaned off the battery terminals and attached the winch leads, covering the terminals with dielectric grease. I also used this on the winch connectors. I sleeved the battery cables where they passed through the frame rails and zip tied everything together. I had just enough cable, too.
I also measured for a gas tank skid plate which will get installed later on.
Here are the pictures:
Andrew wanted to get a full bumper with a winch, but, like most of us these days, funds were short, so we agreed to do the winch first, then do the bumper later on. This posed a couple of problems as I had to mount the winch plate in such a manner as to have it both functional and removable for the final bumper installation. Generally, the winch plate would be mounted permanently with only the winch itself being removable (the way I would mount it anyway). In this case, I wanted to bury the winch in the frame rails behind the existing stock bumper. When the new bumper is designed, the winch will be moved to the top and we will lose some of the frame to improve approach angles. I used a piece of 2x4x3/16for a frame stiffener and back mount for the winch. This I welded in place and bolted the backside of the mount to it. I also used some 2x2x3/16 angle for the font mounts that were also welded to the frame and bolted through the mounting plate. I welded the plate to the frame with two stitch welds to the back of the plate on the bottom side as additional reinforcement. These can easily be ground off when the new bumper is built.
He got a very nice 10.5K Superwinch and we used a universal mounting plate from MileMarker that was 36" long. This was actually a pretty good deal at $70 and is certainly stout enough. Being a 'universal' mounting plate, there were some modifications needed, but they were minor. I had to notch for the frame rails, then drill out the fairlead holes so that I could use the 1/2" bolts I wanted to use. I also need to drill out some of the existing 3/8" to 1/2" for the same reason for the frame mounts.
I located the winch on the mounting plate, put it on a floor jack and and started measuring to see what and where I needed to cut. Rather than trim the plate, I cut off the inside of the lower bumper mounts so that the winch and plate could slide forward enough to get the fairlead to the front of the lower bumper. Then I trimmed the inside of the lower bumper and cut out the outside to expose the fairlead. This worked well and managed to move the clutch lever far enough forward to clear the radiator mount.
I then cut and drilled a piece of 2x4 steel for the rear mount of the winch, which I bolted the back of the plate to. This piece was welded in and will act as reinforcing for the front of the frame rails. The sides of the winch plate were bolted to steel angles that are welded to the inside of the frame rails.
I notched the front top of the bumper to ease access to the clutch so that you can use it easily with the hood down once the remote is in place. Then I cleaned off the battery terminals and attached the winch leads, covering the terminals with dielectric grease. I also used this on the winch connectors. I sleeved the battery cables where they passed through the frame rails and zip tied everything together. I had just enough cable, too.
I also measured for a gas tank skid plate which will get installed later on.
Here are the pictures: