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[Nexus]

Well I have started the fabrication / modification of the bumper to fit the winch to my existing Warn Rockcrawler the photo's that follow show the progress to date.

Warn Rockcrawler at the start



Rear 2 3/4" x 2 3/4" x 1/4" stitched in place



Rear 2 3/4" x 2 3/4" x 1/4" Trial fit TIG welded both sides, holes drilled to pick up front swaybar mount.



Side plates added, and TIG'ed all round



2" x 1/4" plate TIG'ed on centre line of winch fixing holes to thicken locally to 1/2"



this is as far as I have gotten at the moment as I am going to order the winch in the week so I can check fits, clearance before drilling the fixings.  I will then fabricate the support for the fairlead.  Is their a general rule of thumb for the vertical position of the fairlead I am assuming the centre of the opening is on the centre between drum empty and drum full.

Cheers
Nick

[Warthog]

The hawse slot top edge, level with bottom of drum. Does that make sense?

Something you may like to consider is, mounting the winch with the 4 mounting bolts facing forward? Facing forward could be an option to make the plate design more effective for mounting the winch?  It is common to mount them this way on Recovery trucks and military vehicles, as the winch then pulls against the 4 winch mounting bolt location areas. Rather than in a shear plane to the bolts.

But it can make it easier for some thieving asswipe to nick your winch

Hope that helps, just letting ya know stuff i have picked up on the way

[Nexus]

Warthog, thanks for the info by bottom of drum I am assuming this when it has no cable on, so the first layer wouldrun against the top roller then move away on layer 2, etc towards the bottom roller.  I am mounting the winch feet down and am going to incoroporate a method to lock the winch to the bumper to stop some thieving beggar walking off with it.  Also all of the fixings from the bumper are going to be changed to 10.9 or 8.8 grade depending on whether they are Metric or US I think they are metric.  Due to the cable spooling off of the bottom I think the fixings see more shear load than tensile as the drum is trying to pull itself down, plus I have already welded the plates in to bolt it down through.

Cheers
Nick

[doublej]

looking good, when you do the fairlead mount also thinking about either making it big enough to protect the winch from getting smashed up or you can add some tube work

[Warthog]

Warthog, thanks for the info by bottom of drum I am assuming this when it has no cable on, so the first layer wouldrun against the top roller then move away on layer 2, etc towards the bottom roller.
YEP, Thats right
Due to the cable spooling off of the bottom I thnk the fixings see more shear load than tensile as the drum is trying to pull itself down, plus I have already welded the plates in to bolt i down through.
Just sketched out, the 2 layouts and can see how your thoughts are warranted
Cheers
Nick

Looking good 

[Nexus]

Thanks Warthog, DoubleJ at the moment the fairlead support is just going to support the fairlead but I am considering bending some tube to make a hoop but need to do a few sketches as I don't want it to look to fancy.

Cheers
Nick

[doublej]

best and simplest ive seen (and even fully saved the winch in a really bad roll) for nothing but winch protection

if you look close you can see the black bar over then winch. from the back of the bumper to the top of the fairlead. heres the full build....
http://www.pirate4x4.com/forum/showthread.php?t=451569&page=17

makes the fairlead plate alittle smaller with a better shape and it should come out hot.

[momos]

  that is cooool!

[Nexus]

Looks like I will need to go and look for some tube then to fabricate some form of guard, the winch arrives on Thursday so I will look into it at that point as I can see what I am trying to protect.

Cheers
Nick

[doublej]

do u have a way to bend it? i can bend 1 3/4 if ya need it.............

[Nexus]

I have a 12 ton hydraulic pipe bender with upto 2" forms that I will have a go with once I decide size shape, etc.  Thanks for the offer anyway.

Cheers
Nick

[normalbloke]

That looks very good sir!Look forward to the finished pics.
Myself and a pal are making a mount for the new front winch for my Mog, the base plate is 800x300x20mm thick.It's a PITA as it takes 2 of us to mount it up for every measurement we need to take!

Good luck with your project!

[doublej]

not to hi-jack but why is it that thick? unless if helps lower your front end to the desired ride height

[normalbloke]

not to hi-jack but why is it that thick? unless if helps lower your front end to the desired ride height

It's because the winch thats going on is going to mean that the mounting shaft is going to sit out from the ends of the chassis slightly.Rather than brace,weld,brace some more,we decided to go with plate.It is also to help clear the PTO shaft.