Stage II - bigger, heavier, slower.

[rstrucks]

I cut out some more metal to make some more room for the winch. I'm using 1/8" angle to add some strength to the 3/16" plate I'm using to mount the winch on.





I also added some angle iron to the bottom of the factory crossmember. I'm not sure how yet, but I plan on tying the bumper into this somehow. Just to spread any winching loads out.



Snuck the winch wiring through. I do plan on removing the winch for street use so it should be pretty easy. The connector will be hidden once the grill is reinstalled.



I wanted the winch to sit as low in the bumper as possible without hindering approach angle too bad. It sits as far back as I could get it without having to hack up too much.








I'll add a fairlead mount to it next.

[SirFuego]

I like how close it is -- but are there plans to add in some more metal to protect the winch?

[rstrucks]

I like how close it is -- but are there plans to add in some more metal to protect the winch?

Yeah, I'm thinking a really simple protective hoop over the top/front edge would be good. I just don't want it to look goofy when the winch is pulled.

[chadjans]

Winch plates should be made out of 1/4" material.

[ATL ZJ]

Winch plates should be made out of 1/4" material.

Looks to me like it's 5/16" where it mounts, and unlike a lot of other winch mounts, even has support in both x and z planes from the perpendicular edge of the angle iron. Normally I would agree with you on 1/4" being a hard and fast rule, but there can always be exceptions for good designs.

That's coming from a guy who is likely to be nearby when that cable is spooling in too.

[AgitatedPancake]

That seems like a pretty damn solid design to me, I'd have no problem trusting it either.

Nice work man! Looks good too.

[greengc4x4]

How much space do you have between the grill and winch?

[paulkeith]

lookin good ryan.

you're not going to cut up that coveted 5.9 grill for a some stupid "winch" thing are you?!?

[Jeeptech01]

If you plan on removing the winch alot you could make the fairlead slip into the reciever on the front. That way it would still look like a non winch bumper somewhat.

[rstrucks]

I'm not worried about the strength of the mounting plate at all. The way it is all tied together should make up for the missing 1/16".


Paul, I'm going to try to make it up to Pull-a-Part before GSSE-W so I can grab a spare steering box. If I do I'll grab a grill to cut up as to not sacrifice the coveted 5.9 grill. If not, I'll just run without one.


JeepTech, the reason I didn't finish the fairlead mount is for just that reason. I needed to grab some 2x2 tubing to see if I could do just that. I don't want it to be too bulky or worsen approach but it would make it really easy to change to winchless mode.

[paulkeith]

OK, phew.


Any thought to a synth rope and hawse fairlead? too $$?

[rstrucks]

Thought about it. It will probably be steel wire for a while until I gather the $$$. There are too many benefits to the synthetic to ignore it though.

[zjeepin]

I'm not worried about the strength of the mounting plate at all. The way it is all tied together should make up for the missing 1/16".


Paul, I'm going to try to make it up to Pull-a-Part before GSSE-W so I can grab a spare steering box. If I do I'll grab a grill to cut up as to not sacrifice the coveted 5.9 grill. If not, I'll just run without one.


JeepTech, the reason I didn't finish the fairlead mount is for just that reason. I needed to grab some 2x2 tubing to see if I could do just that. I don't want it to be too bulky or worsen approach but it would make it really easy to change to winchless mode.

ryan, ive got a spare waggy box i'd like to get rid of.. I can bring it to windrock.. its cheap too

[rstrucks]

Is it in good shape? How much? It's nearly a direct swap isn't it? I know - search, and I will, later tonight.

[ATL ZJ]

Is it in good shape? How much? It's nearly a direct swap isn't it? I know - search, and I will, later tonight.

yep it's super easy. I will have a drill there too, if worst comes to worst.

just cut the grill!

[zjeepin]

Is it in good shape? How much? It's nearly a direct swap isn't it? I know - search, and I will, later tonight.

yeah, its in good shape took it off when i went full hydro..

bolts right in plus 4th bolt hole and lower reduction gears. you just need to cut the o-ring seal off your high pressure ps hose and flare it, i have a couple pressure lines i'll give you with it so you don't have to mod yours on the trail should catastrophe occur.. case of beer?

uh cam, whats the drill for?

[Jeeptech01]

You could even do some type of light bar that would run across the front near the winch and hang some lights off it too. That would hide the winch plate when not in use. Hell you could even make that removable too so you could take it off for better approach on the rocks. I thought you had mentioned a bar or hoop of some sort earlier.

I thought that hp30 looked a little wierd when I started reading the thread then I remembered this is the soccer mom rig right?

[ATL ZJ]

uh cam, whats the drill for?

It lives in my big wheelin tote, so it goes everywhere. Last time I remember it coming in handy was for some toyota knuckle studs.

[zjeepin]

i thought you intended it for the steering box install...

[SirFuego]

Drill for the 4th bolt of the waggy box?

[ajmorell]

Drill for the 4th bolt of the waggy box?

That's kinda what I figured too

[zjeepin]

well, you need a welder more than a drill for that part.. the 4th bolt hole is above the unirail..

[ATL ZJ]

I just drilled mine and added a spacer between the "inner fender" and box. In retrospect, maybe that's why I broke so many 4 bolt boxes. I can bring that part of my unirail to windrock for mockup too if you want.

[zjeepin]

I just drilled mine and added a spacer between the "inner fender" and box. In retrospect, maybe that's why I broke so many 4 bolt boxes. I can bring that part of my unirail to windrock for mockup too if you want.

i did something similar but actually welded the spacer tube to the rail.. only broke one 4 bolt box and i think it was due to a massive amount of bumpsteer after the 60 install..

yeah, bring that chunk of unirail

[CrawlerReady]

I love how tucked back that winch is! So are you cutting the grill out to fit around it or does it just fit snug against it? (can't tell from the pics) My winch has ~1/2" gap between it and the grill and it looks like it sticks out much further than that.