Birty Dastards Jeep Club

Tech Forum => Workshop => Topic started by: Nexus on September 27, 2009, 03:10:23 PM

Title: Front bumper mod/fabrication for winch - Part 2
Post by: Nexus on September 27, 2009, 03:10:23 PM: Okay part two of the modifications/fabrication to fit the winch to the front of the TJ. Since the previous thread I have purchased the winch, I finally decided on the Goodwinch TDS9.5C which arrived last week.

The first job I carried out was to drill the winch fixings through the previously fabricated support on the Warn bumper. Once this was done I could start to fabricate the support for the fairlead. the first step was to attache the main angles that the fairlead would bolt to / through.

(https://birtydastards.com/frm/proxy.php?request=http%3A%2F%2Fi661.photobucket.com%2Falbums%2Fuu338%2FNexusJeep%2FWinch%2520Bumper%2FImage06-Fairleadangles.jpg&hash=2ab7f793a4016aeb6aca6f98d1ee3952d7e51242)

Once they were in place and I had refitted the winch and fairlead to check alignment / clearance I created braces to support the original angles and welded these in and then carried out a little shaping on the original angles with the angle grinder.

(https://birtydastards.com/frm/proxy.php?request=http%3A%2F%2Fi661.photobucket.com%2Falbums%2Fuu338%2FNexusJeep%2FWinch%2520Bumper%2FImage07-FairleadBraces.jpg&hash=8e741c7df1ed63369aa3abded9ca43493fe22604)

This completed the actual sticking bits together with metal glue part of the fabrication. I then sandblasted the whole thing, acid etched and zinc phosphated it. The base was two coats of POR15 followed by two top coats of Satin black.

(https://birtydastards.com/frm/proxy.php?request=http%3A%2F%2Fi661.photobucket.com%2Falbums%2Fuu338%2FNexusJeep%2FWinch%2520Bumper%2FImage08-BlastedandSprayed.jpg&hash=e2fcb51108634f027a42a9bc1251c0e8d481a701)

The next stage was to attache the winch to the bumper as the front winch fixing bolts are inaccessible once the bumper is on the TJ. The whole thing was then lugged out to the front of the house and beaten into place on the front of the chassis. This was then secured using grade 12.9 fixings.

(https://birtydastards.com/frm/proxy.php?request=http%3A%2F%2Fi661.photobucket.com%2Falbums%2Fuu338%2FNexusJeep%2FWinch%2520Bumper%2FImage08-Fitted1.jpg&hash=b9f9221766e22dbbbc5947680be54e057a53e8c3)

The body work was drilled and the isolator switch + cables routed through the front panel, this necessitated the removal of the front headlight.

(https://birtydastards.com/frm/proxy.php?request=http%3A%2F%2Fi661.photobucket.com%2Falbums%2Fuu338%2FNexusJeep%2FWinch%2520Bumper%2FImage09-Isolator.jpg&hash=93c9a2bf2639d8874d828c10584f880abebd78b3)

The two allen bolts in the image below locating the cable will be replaced by a proper cable tidy later in the week.

(https://birtydastards.com/frm/proxy.php?request=http%3A%2F%2Fi661.photobucket.com%2Falbums%2Fuu338%2FNexusJeep%2FWinch%2520Bumper%2FImage10-Fitted2.jpg&hash=6d3d4e1125119df9d48707e7c859633017b8b2d8)

And finally a shot from the other side.

(https://birtydastards.com/frm/proxy.php?request=http%3A%2F%2Fi661.photobucket.com%2Falbums%2Fuu338%2FNexusJeep%2FWinch%2520Bumper%2FImage11-Fitted3.jpg&hash=b46b9118011f794eeb08238b84c20bfe1098d292)

The other thing I plan to make is a velcro strap to hold the hook clear of the licence plate and also a push over cover for the isolator to keep the elements / crap out.

Cheers
Nick
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: daggie on September 27, 2009, 04:15:37 PM: :greggmo: very neat :icon_super:
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Nosebolt on September 27, 2009, 04:24:24 PM: I like :003:

very pleasing to the eye and looks like it will do a good job too, well done there m8
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Bubba on September 27, 2009, 05:12:17 PM: i like everything sept the isolater but they are a pain whatever you do anderson plugs are for easy theft or to double as jump starts ?
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: momos on September 27, 2009, 05:37:37 PM: OH oh body coloured winch! nice! :icon_biggrin: :icon_biggrin:
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Nexus on September 27, 2009, 06:12:15 PM: V8Bubba Anderson plugs are for slaving/jumping purposes, to remove the winch you need to remove the bumper, can't ever stop it being nicked just make it difficult hence the cover over the two bumper fixing bolts and padlock.

Momos, the winch came that colour it is just luck that it's similar to the Jeep.

thanks for the replies.

Cheers
Nick
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: greggmo on September 27, 2009, 10:34:16 PM: lookin good dood. :greggmo:
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Bubba on September 28, 2009, 05:00:50 AM: is that a guppy winch
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Nexus on September 28, 2009, 08:06:58 AM: Nah its a Goldfish, the Guppy was the big plane that delivered Concorde parts to Filton.

Cheers
Nick
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Warthog on October 03, 2009, 01:03:38 PM: Thats a nice Job :023:

Are you sure of the number plate location? You'll reverse at some point and rip it off :003: A removable number plare set-up like Asylums is good option.
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Nexus on October 03, 2009, 03:01:30 PM: The number plate is still on going as I am thinking about a couple of options, but I needed something to be able to drive it if I am going off road then temporaily I can take the screws out to remove it.

Cheers
Nick
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Bubba on October 03, 2009, 03:07:38 PM: years ago i used to do compete with awdc and i fitted my no plate on hinges yup it looked odd flapping about under the bumper but i never broke it once
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Nexus on October 03, 2009, 05:53:55 PM: Perhaps a James Bond style revolving one would work :003:

Cheers
Nick
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: isle of man on October 03, 2009, 06:54:03 PM: Nice work.....
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: gazjeep on October 04, 2009, 10:54:56 AM: Quote from: Nexus on October 03, 2009, 03:01:30 PM
The number plate is still on going as I am thinking about a couple of options, but I needed something to be able to drive it if I am going off road then temporarily I can take the screws out to remove it.

Cheers
Nick

If it helps, I have fixed ours on as you can see in the pics, even though the bumper is angled down & its gone through a couple of MOT's no problem.

Rather than drilling any holes, its fixed with double sided 3M hard velcro like this

http://cgi.ebay.co.uk/3M-DUAL-LOCK-SJ3560-UP-TO-8X-STRONGER-THAN-VELCRO_W0QQitemZ330363399633QQcmdZViewItemQQptZUK_DIY_Material_Nails_Fixing_MJ?hash=item4ceb316dd1&_trksid=p3286.c0.m14 (http://cgi.ebay.co.uk/3M-DUAL-LOCK-SJ3560-UP-TO-8X-STRONGER-THAN-VELCRO_W0QQitemZ330363399633QQcmdZViewItemQQptZUK_DIY_Material_Nails_Fixing_MJ?hash=item4ceb316dd1&_trksid=p3286.c0.m14)

If you have concerns about it coming off will playing, just remove it till you want to go home, simples[attachment=1][attachment=2] :003:
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Bishops Finger on October 04, 2009, 09:35:44 PM: Get hold of a Wizard Landy one..it fits on the fairleads...got one on my TJ...
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Nexus on October 06, 2009, 08:13:49 AM: Thanks Gazjeep velcro's a possibility, Bishop do you have a link to the "Landy" (Feel dirty having typed that) wizard one as I keep find custom motorcycle parts when I do a search.

Cheers
Nick
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Bishops Finger on October 06, 2009, 12:52:43 PM: Think its this chap

http://stores.shop.ebay.co.uk/Wizardbilt__W0QQ_armrsZ1 (http://stores.shop.ebay.co.uk/Wizardbilt__W0QQ_armrsZ1)
Title: Re: Front bumper mod/fabrication for winch - Part 2
Post by: Nexus on October 06, 2009, 01:26:59 PM: Thanks Bishop definitely a consideration as from description I can fairly easily make one.

Cheers
Nick