Stock bumper with hidden winch (details/pics)

[xcntrk]

I built a winch tray that hides between the frame-rails and allows use of a compact winch behind the stock bumper. I posted some pics on FB and there’s been some interest in more detail, so here it goes with pics:


Let's start with a few pics of the finished product, then go over the build process:

Here is the finished unit:

Top - winch tray. Mounts between the rails, bolts vertically to the sides of the frame, and has a horizontal mount to the bottom of the frame. Also serves as a swaybar mount and reinforcement.

Middle - bumper reinforcement plate. Sits between frame-rails and behind stock bumper to reinforce hawse fairlead.

Bottom - skid plate. Ties between bumper and winch box. Helps protect winch box which hangs down from frame rails.

 

[xcntrk]

The build process...

Started with a winch that was selected for it's narrow size being able to fit between the frame-rails. Also chose synthetic cable in order to use a hawse style fairlead for a sleek and stealthy finished product. Ended up with a Smittybilt XRC 9.5:

http://www.4wheelparts.com/Winches-...aspx?t_c=18&t_s=300&t_pt=100702&t_pn=S/B98495

Once I had the winch, I started some mock up fitment using simple lauan plywood.

Once I finalized the design and had a working template, I set off to build the unit for realz. Dropped my jigsaw (I hate wooodworking) and picked up the plasma cutter:

Once I had the winch box pieces, a few bends in the press to finish off the main structure:

More welding, more cutting, more bending, and here's the nearly finished rough product:

Test fit:

...and that's it.

 

[elan]

Being a pipeliner..........I admire your work of art. Nice job.

 

[Teal68]

very nice work!

 

[Unknown]

Very nice!

 

[surfer-b]

Looks good, I like it. Plus it keeps the weight of the winch closer to the front axle. When I added the bumper and winch to my 76 I could tell there was some added weight on the front when driving, nothing bad but it was noticeble

 

[pipermike]

Your work is always top knotch looks great.

 

[xcntrk]

A few more details...

The winch clutch handle is accessible from within the engine bay. Since the winch sits direction in front of the engine cross-member and behind the radiator, you have to reach down in front of the engine to disengage/engage the clutch. Not the quickest access, but easy enough.

The winch solenoid box is remote located in the engine bay. It's hidden away and the winch control interface plug is relocated up near the top of the grill for easy plug-in access.

Additionally I have in-cab winch controls accessible from the driver seat:

 

[Mountain Ram]

Nice job!

 

[bowhunter]

Very Nice!

 

[904Bronco]

Very Clean job!

 

[72_EB]

Sexy.

 

[mudstud]

I like it. When do you start production

 

[smokinjoe]

Love it!! So subtle but functional!! Perfect for LUBERS, I echo mudstud, when is production starting?

At the very least you need to patent the idea or something and sell the design to a supplier.

 

[kb6677]

Looks good with the chrome bumper- also like it with the stock oxford white bumpers- Completed in '09-'10

 

[Jeff10]

Hey Anthony,

You're the man!

You make me want to spend more time working with my tools... although there's certainly a difference in skill level that would take me time to overcome.

Nice job.

Jeff

 

[House]

You should pass on the design to a production facility if it isn't a product you want to pursue. Great job!

 

[duffymahoney]

Awesome design and work!

 

[markw]

Anthony, I would very much like to copy that! Are the drawings in your head or on paper somewhere? Very cool design and execution. Thank you for sharing that! Mark

 

[markw]

Let me clarify....I would gladly pay you for drawings!