Winch Mount Retaining Stock Bumper and Look

[skerrybronco]

Here is what I have so Far as fitment

I will be doing summer daily and weekend picnic trails nothing to hard core
I say that now he he
did all that with a previous heep build.
That said I still want the security of having a winch, but still want to retain the stock look as much as possible, so the fab starts
see photos, if I get enough interest I will try a tech write up

 

[mofoco1]

That looks very cool. Wont work with the larger winches though as know space is at a premium. I am doing something similar but with an 8274M which will not fit in that space due to it's design, but I wanted it as unobtrusive as possible. Here's mine. Been on hiatus due to weather, am flap wheeling some more in just a a bit. What are you using as bracing for the stock bumper, as those fold over very easily in stock form? A couple of pics of others when I was researching for my build. Good luck and for sure post more pics.

 

[bigpitbull]

Looks very cool. What winch is that?

 

[skerrybronco]

Nice Fab work,I seen this thread as well when I was researching.
I had the 8274 on my jeep and built not to big a bumper, the winch of all winches imo, but big and heavy, and you have more space on a jeep
I wanted something smaller and stock looking
the photo of the hawaii truck looks tucked up in there...

To Mount I started with a rough country tj yj winch mount plate, half the work is done, just need to modify, got a deal on a new rugged ridge 8500,Did some research and they are all about the same size 6.5Hx6.5D, unless you can afford the
little warn 9.5rc.
The free spool lever needs to be flipped, so its pointing down.
Took the cable off,will be using a rope out the middle of the bumper.
plate will be bolted to the bottom of the frame, still at fitting stage, may weld some small plates at 90 degrees on each side to bolt to the inside of the frame rails
Will be mounting the solenoids behind the grill
will keep posting when I get back to it

 

[xcntrk]

Great work!

I've been considering doing the same. My vision is to sink a winch between the rails and build quite a bit of reinforcement through and around the frame horns. Also to span further beyond the horns on each side to aid in crash/bumper protection. Think like a bumper reinforcement backbone behind the stock bumper. In my design I would have to push the bumper out a small bit to accommodate the additional structure, but would still retain that "classic bumper" look.

Great work here, can't wait to see the finished results.

 

[skerrybronco]

I have also thought of that will probably use some tube work, my local 4x4 vender
has a bender and they are buddies.
basically the bumper will be about .5 in. forward and 1 inch down from stock position
but dont forget I have a 2 inch body lift

 

[mofoco1]

3" BL on mine, I moved everything up to hide it.

 

[skerrybronco]

I was allowed to work on the bronco last night.......;D
Got the hole cut for the hawse to mount on bumper, also had to open up the opening on the winch mount......

 

[mofoco1]

Nice job, it's looking good.

 

[Fireball05]

Looking good. I love the idea of maintaining the stock bumper. Please keep us posted with your progress!

 

[JLBachs]

That bumper looks so clean I won't make any unruly remarks about what looks to be a bowtie on your shirt.

 

[skerrybronco]

Thats funny, didnt realize I was wearing that T shirt when the wife snapped the photo
anyway Ive owned fords heeps chebbys and now have the EB
And a t shirt from this site its a beauty
thanks for the praise on the bumper guys, will post more when I get back to it

 

[904Bronco]

I was allowed to work on the bronco last night.......;D.....

You got it wrong.... You were authorized to preform upgrades on the Bronco ;D

Nice work... This might look good on my 68!

 

[BronCowie]

Very nice. I'm afraid I will have to copy your design some day.

 

[skerrybronco]

Got to play with the mistress again
So you see in the photos I needed to trim some of the rad hanger brackets, not sure thats the right terminology.
Had to trim 2 notches out of the bottom of the bumper to clear the bolts that mount the winch.
Before I went into the Garage I took a Robaxacet as I get a sore back from lifting this stuff alone, take it apart drill grind put it together fit it, and repeat and repeat....
The bumper will fit over the frame about half an inch out from stock, so I can not utilize the original holes, I think I will drill and tap 2- 3/8 holes on each side of the hole to secure it, and put a small bolt with a large washer to cover the original for aesthetic purposes.
Marked and drilled for 2-1/2 holes on each side of the plate to mount underneath
still need to drill the frame and continue
I will continue posting when I can
cheers

 

[mofoco1]

That looks great. Finished mine too, need the rope still , but it's now on to the rear hitch/raised stock bumper build.

 

[skerrybronco]

Looking good
If you use rope, i thought you need poly rollers, I have a set Idid not end up changing on the heap
I would send them to you
But your fair lead does not look common

 

[mofoco1]

I actually am trying to get some SS cable, holds up better than the zinc cable. They say that you are supposed to use poly or an aluminum hawse with the rope, but I have seen them use regular rollers. Mine are just smaller on the sides, the other 2 are regular size. I think they shy away from the rollers as they said it may pinch the rope. I thank you for the offer though, now if you have a 150ft length of SS 3/8" cable I will gladly take that off your hands;D I was unpleasantly surprised to find out that wire rope prices as everything else has skyrocketed Going to go to the local rigging shop 2 blocks away and compare prices + local tax over online. Again your bumper will be emulated on a future build. haha

 

[skerrybronco]

Got back to it this weekend. Winch plate is now bolted to frame, Would have liked to mount solenoid box behind grill, but there's just not enough room, so for now I opted for behind the bumper. Modified the box so the control plug is at the top,
Had to cut and bend up a section below the grill for clearance of the power wire mounts on the winch motor, also put plastic door edge trim to protect
the wires just incase. Put the wires to the battery so I could try it out and spool the rope on and of course the battery is dead sitting about three months now.
this will be for another day........

 

[xcntrk]

Looks great, what a neat project.

One bit on of constructive criticism, I'd be a bit weary mounting the winch plate to only the bottom portion of the frame horn. Seems entirely feasible that you could rip off that lower horn and the entire winch would come with it. An easy fix would be to sleeve inside the frame horn and use 2 long bolts that mount through from top to bottom. You could either sleeve using round tubing for each 1/2" bolt, or use rectangular tubing that fills the entire frame and is drilled for the bolts to pass through. Just a thought.. Looks great either way...