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How to: Winch Install on a 2nd Gen - Factory Bumper

Discussion in 'Offroad Fabrication - Bumpers, Sliders, Cages etc.' started by turboexplorer, January 4, 2015.

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    1. turboexplorer

      turboexplorer Elite Explorer

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      I am 114 1/16" :) So dead on the same as yours.
       
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    3. turboexplorer

      turboexplorer Elite Explorer

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      So onto catching up winch pictures. Winch fitted on plate after plate was completed.
      View attachment 82077

      Factory transmission cooler location.
      View attachment 82078

      This will be the new location.
      View attachment 82079

      Making sure the lines will clear.
      View attachment 82080

      Starting the lower cooler mount. Made a simple mount out of 1/2" wide 1/8" flat stock. Turned the legs sideways as to not impede any air flow. (not that it would matter any lol)
      View attachment 82081

      Mocked up into place. I used all 3 factory cooler mounts with original hardware.
      View attachment 82082
       

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    4. turboexplorer

      turboexplorer Elite Explorer

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    5. turboexplorer

      turboexplorer Elite Explorer

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    6. turboexplorer

      turboexplorer Elite Explorer

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      Wires crossing the frame rail to reach the winch motor.
      View attachment 82094

      Do you see the power wire for the winch? Me either, it's hidden. It is inside the upper section of the front fiberglass core support. It is just under the black trim piece you see sitting up in place on the top. It is inside it as it is U shaped.
      View attachment 82095

      Wires hooked up to the winch motor and old trans cooler lines coming through their routing. Think I am going to redo the hard cooler line ends so the rubber section can go on the side of the radiator instead of under it.
      View attachment 82096

      Bumper back on with winch in place.
      View attachment 82097

      Holding the fairlead roughly where it will end up being mounted.
      View attachment 82098
       

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    7. turboexplorer

      turboexplorer Elite Explorer

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      So onto the fairlead mount. First held bumper in place did a bunch of measuring and then laid it out onto my CAD. After the rough size was there and the shape of the fairlead was drawn onto it I could then better see how I wanted the mount to look and where I wanted the support. All this is made from 1/4" plate and all cut out with a 4 1/2" grinder with a cut off wheel.
      View attachment 82117

      So this is what I decided on for the mount design. It is strong and ties both sides of the mount together as well as keeps a very minimal footprint that you can see from the front of the truck. Also when you see it done you will see how it will act as sort of an arch and will also ad a bit of strenghth to the plate from flexing at all when the winch is twisting. I also center punched the fairlead mount holes through the pattern so it was all done in one shot no guessing.
      View attachment 82118

      Cut out.
      View attachment 82119

      Fairlead sitting on it, love how its the same angle as the fairlead aluminum.
      View attachment 82120

      Rest of the mount cut out.
      View attachment 82121

      All sanded and edges all rounded and corners rounded for a nice clean look. Also easy to handle as it is smooth everywhere.
      View attachment 82122
       

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    8. turboexplorer

      turboexplorer Elite Explorer

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      All mocked up and ready to be welded. I used a piece of 1/4" plate under it so that the mounting surfaces would be perfectly flat and in line.
      View attachment 82123

      All welded up.
      View attachment 82124

      Fairlead attatched.
      View attachment 82125

      Mocked up on the winch plate.
      View attachment 82126

      View attachment 82127

      Fitted the bumper so I can make sure it is exactly what I want. and is placed perfect. Then mark so some mounting holes can be drilled. Also I did end up needing to cut about 1/4"X1/2" off of the inside of the bumper where the lower corners of the fairlead mount at fitment issues. Easy fix. I have at least 1/4" between any part of the fairlead and any part of the bumper.
      View attachment 82128
       

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    9. turboexplorer

      turboexplorer Elite Explorer

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      All bolted up! Here you can see where the fairlead mount can act as a sort of arch and add a bit of flexing strenghth to the front of the winch plate.
      View attachment 82129

      View attachment 82130

      View attachment 82131

      Made the remote plug socket mount onto the fairlead mount at the end as I thought it would add a nice clean look to it and will be easy access to plug in. Also didn't have to drill any holes for it else ware.
      View attachment 82132

      View attachment 82133

      All stripped down and taped off and ready to be painted. Finally, as usual the project took longer than I thought it would. Last Saturday had a huge migraine so didn't get anything done so that didn't help either. But very happy with how it has turned out. Was a chore getting it to fit really cleanly behind the factory bumper but I got it done.
      View attachment 82134
       

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    10. MidnightRebel07

      MidnightRebel07 Elite Explorer

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      Nice work.
       
    11. RockRanger

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    12. turboexplorer

      turboexplorer Elite Explorer

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    13. turboexplorer

      turboexplorer Elite Explorer

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    14. turboexplorer

      turboexplorer Elite Explorer

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      Got the pigtail for the remote control extended 18" and had the wife braided it for a nice really clean wire. Was a good thought I'll have to remember this for other projects. Looks really clean compared to 3 random wires.
      View attachment 82198

      Got the chrome part of the grill all plasti dipped. It turned out pretty good. I kinda suck with it, it always wants to peel around where I tape off. But either way it turned out great for a temporary look. I really like it.
      View attachment 82199

      Winch control solenoid box is mounted for the final time. This is where the power wire for the winch is run, it runs straight up from the solenoid box to the upper section of the fiberglass support. Nice and clean and no way to ever rub on any metal since this large wire is not fused or breaker-ed.
      View attachment 82200

      Nice and hidden.
      View attachment 82201

      And where it does duck through the core support I did 2 layers of heat shrink tubing so as not to run into any issues.
      View attachment 82202
       

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    15. turboexplorer

      turboexplorer Elite Explorer

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      Winch is fully mounted and wired in for the final time. Winding up the rope onto the winch drum. I will have to spool it out and do a proper rope spool with it pulling the rig on flat ground to make sure its tight enough so the rope doesn't fall in between itself and get stuck when I am doing an actual recovery pull.
      View attachment 82255

      All spooled up and fairlead mounted in place. Looks awesome tucked in there. :D I love how the fairlead mount turned out!
      View attachment 82256

      View attachment 82257

      View attachment 82258

      View attachment 82259
       

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    16. turboexplorer

      turboexplorer Elite Explorer

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      Front bumper refitted and alined for the final time with the winch rope fed through. I also did a full wipe down of the fiberglass support since I was in there it might as well be fully cleaned. Compare to the bottom picture in the last post.
      View attachment 82260

      And the final product with the winch fully in and the chrome portions of the grill are now plasti dipped white. I really like how the winch turned out, it is very simple and really really clean looking. Turned out just like what I had in mind. I also really like the white grill.
      View attachment 82261

      View attachment 82262

      View attachment 82263

      View attachment 82264

      View attachment 82265
       

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    17. turboexplorer

      turboexplorer Elite Explorer

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      Winch Install on a 2nd Gen - Factory Bumper

      I have had several people ask me to make a winch install write up for behind the factory bumper. They have asked to make a separate thread so that when it is searched it will come up easier than scrolling through my long build thread.

      Any chance a moderator can copy posts 706-746 from my build thread to this thread? Not sure how it works but would be the easiest rather than going through all my pictures again. But would still like to leave the posts in the build thread as well.

      [MENTION=71]Rick[/MENTION]
      [MENTION=8557]james t[/MENTION]

      If not let me know and I can spend some time going through it again.
       
    18. Rick

      Rick Pumpkin Pilot Staff Member Admin Elite Explorer

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      Done:chug:
       
    19. turboexplorer

      turboexplorer Elite Explorer

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      Awesome thanks [MENTION=71]Rick[/MENTION]. That was a lot easier than redoing all the posts.
       

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