- Joined
- Oct 13, 2010
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Toyota Dyna Winch Bumper
I had another busy week at work, only a short one as Monday was a public holiday as it was the Queens birthday.
I've been busy working on my bosses latest toy, his tip truck.
I needed to replace the rotten front cross member and build a new front bumper with a big 12,000LB winch mounted in it.
![DSCN0703_zps8qvrbknn.jpg DSCN0703_zps8qvrbknn.jpg](https://www.landcruiserclub.net/community/attachments/dscn0703_zps8qvrbknn-jpg.97912/)
The rotten cross member was riveted in position so I had to grind the heads off the rivets and punch them out.
![DSCN0705_zpsgckp1xfz.jpg DSCN0705_zpsgckp1xfz.jpg](https://www.landcruiserclub.net/community/attachments/dscn0705_zpsgckp1xfz-jpg.97913/)
![DSCN0706_zpsam6firph.jpg DSCN0706_zpsam6firph.jpg](https://www.landcruiserclub.net/community/attachments/dscn0706_zpsam6firph-jpg.97914/)
I ended up having to slice it down the middle to get it off.
![DSCN0708_zpsqhgrncbu.jpg DSCN0708_zpsqhgrncbu.jpg](https://www.landcruiserclub.net/community/attachments/dscn0708_zpsqhgrncbu-jpg.97915/)
![DSCN0709_zpsszmcgpqo.jpg DSCN0709_zpsszmcgpqo.jpg](https://www.landcruiserclub.net/community/attachments/dscn0709_zpsszmcgpqo-jpg.97916/)
Cut some 90mm x 10mm flat to length and ground the corners off 2 edges to fit snugly in the chassis rails, this would give me something nice and strong to mount the winch off.
![DSCN0712_zpsbpe1kv6l.jpg DSCN0712_zpsbpe1kv6l.jpg](https://www.landcruiserclub.net/community/attachments/dscn0712_zpsbpe1kv6l-jpg.97917/)
Drilled some holes in it to line up with existing holes in the chassis.
![DSCN0713_zpspnuhdrrk.jpg DSCN0713_zpspnuhdrrk.jpg](https://www.landcruiserclub.net/community/attachments/dscn0713_zpspnuhdrrk-jpg.97918/)
Bolted in position.
![DSCN0715_zps3tiwew1g.jpg DSCN0715_zps3tiwew1g.jpg](https://www.landcruiserclub.net/community/attachments/dscn0715_zps3tiwew1g-jpg.97919/)
![DSCN0717_zpswmjxvdfa.jpg DSCN0717_zpswmjxvdfa.jpg](https://www.landcruiserclub.net/community/attachments/dscn0717_zpswmjxvdfa-jpg.97920/)
Cut and drilled some 75mm x 50mm angle to replace the rotten chassis cross member.
![DSCN0719_zpsfzss3q5i.jpg DSCN0719_zpsfzss3q5i.jpg](https://www.landcruiserclub.net/community/attachments/dscn0719_zpsfzss3q5i-jpg.97921/)
![DSCN0721_zpsmq0wd9me.jpg DSCN0721_zpsmq0wd9me.jpg](https://www.landcruiserclub.net/community/attachments/dscn0721_zpsmq0wd9me-jpg.97922/)
Cut and drilled another for the bottom.
![DSCN0722_zpsxwi0v3ma.jpg DSCN0722_zpsxwi0v3ma.jpg](https://www.landcruiserclub.net/community/attachments/dscn0722_zpsxwi0v3ma-jpg.97923/)
![DSCN0723_zpsqtkf8pev.jpg DSCN0723_zpsqtkf8pev.jpg](https://www.landcruiserclub.net/community/attachments/dscn0723_zpsqtkf8pev-jpg.97924/)
Used the oxyacetylene torch to notch out the 90mm flat to allow the winch to sit lower.
![DSCN0728_zpsm0fr9lcb.jpg DSCN0728_zpsm0fr9lcb.jpg](https://www.landcruiserclub.net/community/attachments/dscn0728_zpsm0fr9lcb-jpg.97925/)
![DSCN0729_zpsmzfj63ms.jpg DSCN0729_zpsmzfj63ms.jpg](https://www.landcruiserclub.net/community/attachments/dscn0729_zpsmzfj63ms-jpg.97926/)
![DSCN0730_zps2yawy6dk.jpg DSCN0730_zps2yawy6dk.jpg](https://www.landcruiserclub.net/community/attachments/dscn0730_zps2yawy6dk-jpg.97927/)
![DSCN0731_zpseu22cqbv.jpg DSCN0731_zpseu22cqbv.jpg](https://www.landcruiserclub.net/community/attachments/dscn0731_zpseu22cqbv-jpg.97928/)
With no machine big enough to cut the 200mm x 6mm flat I needed to use for the winch to bolt to, I clamped a straight edge to it and cut it with the 9" grinder.
![DSCN0726_zpsaccqzheq.jpg DSCN0726_zpsaccqzheq.jpg](https://www.landcruiserclub.net/community/attachments/dscn0726_zpsaccqzheq-jpg.97929/)
Drilled it for the winch and ground the mill scale off where I intended on welding.
![DSCN0734_zpsue5w95nd.jpg DSCN0734_zpsue5w95nd.jpg](https://www.landcruiserclub.net/community/attachments/dscn0734_zpsue5w95nd-jpg.97930/)
Prepared the 90mm flat for welding by beveling the edges to ensure good weld root penetration.
![DSCN0735_zpsfzttu3rl.jpg DSCN0735_zpsfzttu3rl.jpg](https://www.landcruiserclub.net/community/attachments/dscn0735_zpsfzttu3rl-jpg.97931/)
Used the trolley jack to lift the piece of 200mm flat up into position and bolted it to the bottom of the winch and tack welded the 200mm to the 90mm.
![DSCN0736_zpscrzzfetj.jpg DSCN0736_zpscrzzfetj.jpg](https://www.landcruiserclub.net/community/attachments/dscn0736_zpscrzzfetj-jpg.97932/)
![DSCN0737_zps2wuiwdem.jpg DSCN0737_zps2wuiwdem.jpg](https://www.landcruiserclub.net/community/attachments/dscn0737_zps2wuiwdem-jpg.97933/)
![DSCN0738_zpsqkwogr3l.jpg DSCN0738_zpsqkwogr3l.jpg](https://www.landcruiserclub.net/community/attachments/dscn0738_zpsqkwogr3l-jpg.97934/)
![DSCN0739_zpsmrpi88ff.jpg DSCN0739_zpsmrpi88ff.jpg](https://www.landcruiserclub.net/community/attachments/dscn0739_zpsmrpi88ff-jpg.97935/)
![DSCN0741_zpsvrh8ketz.jpg DSCN0741_zpsvrh8ketz.jpg](https://www.landcruiserclub.net/community/attachments/dscn0741_zpsvrh8ketz-jpg.97936/)
![DSCN0742_zpsfjay8ynk.jpg DSCN0742_zpsfjay8ynk.jpg](https://www.landcruiserclub.net/community/attachments/dscn0742_zpsfjay8ynk-jpg.97937/)
Front section next, again out of the 200mm x 6mm.
![DSCN0744_zpsy8wvfl2k.jpg DSCN0744_zpsy8wvfl2k.jpg](https://www.landcruiserclub.net/community/attachments/dscn0744_zpsy8wvfl2k-jpg.97938/)
Marked and drilled.
![DSCN0745_zpstw3fj7rv.jpg DSCN0745_zpstw3fj7rv.jpg](https://www.landcruiserclub.net/community/attachments/dscn0745_zpstw3fj7rv-jpg.97939/)
![DSCN0746_zpsgtli213f.jpg DSCN0746_zpsgtli213f.jpg](https://www.landcruiserclub.net/community/attachments/dscn0746_zpsgtli213f-jpg.97940/)
Joined the holes up with the grinder.
![DSCN0747_zpstskp7i0x.jpg DSCN0747_zpstskp7i0x.jpg](https://www.landcruiserclub.net/community/attachments/dscn0747_zpstskp7i0x-jpg.97941/)
![DSCN0748_zpsw3rmvjfz.jpg DSCN0748_zpsw3rmvjfz.jpg](https://www.landcruiserclub.net/community/attachments/dscn0748_zpsw3rmvjfz-jpg.97942/)
![DSCN0749_zpscqng9vvw.jpg DSCN0749_zpscqng9vvw.jpg](https://www.landcruiserclub.net/community/attachments/dscn0749_zpscqng9vvw-jpg.97943/)
The fairlead bolts through the 6mm into the winch. This would mean the winch will be bolted in position with 4 bolts coming up from the base and 2 through the front so should be nice and strong.
![DSCN0750_zps2rj2mely.jpg DSCN0750_zps2rj2mely.jpg](https://www.landcruiserclub.net/community/attachments/dscn0750_zps2rj2mely-jpg.97944/)
![DSCN0752_zpsgi8f3apo.jpg DSCN0752_zpsgi8f3apo.jpg](https://www.landcruiserclub.net/community/attachments/dscn0752_zpsgi8f3apo-jpg.97945/)
Bolted it on and tack welded the 200mm front to the rest of the winch mount.
![DSCN0753_zps0hvqgzy6.jpg DSCN0753_zps0hvqgzy6.jpg](https://www.landcruiserclub.net/community/attachments/dscn0753_zps0hvqgzy6-jpg.97946/)
![DSCN0754_zpssar15yaz.jpg DSCN0754_zpssar15yaz.jpg](https://www.landcruiserclub.net/community/attachments/dscn0754_zpssar15yaz-jpg.97947/)
![DSCN0755_zpskgwpz5n2.jpg DSCN0755_zpskgwpz5n2.jpg](https://www.landcruiserclub.net/community/attachments/dscn0755_zpskgwpz5n2-jpg.97948/)
The winch had to be mounted quite far forward to clear the tilting cab.
![DSCN0758_zpsez5volhz.jpg DSCN0758_zpsez5volhz.jpg](https://www.landcruiserclub.net/community/attachments/dscn0758_zpsez5volhz-jpg.97949/)
![DSCN0759_zpswruquok0.jpg DSCN0759_zpswruquok0.jpg](https://www.landcruiserclub.net/community/attachments/dscn0759_zpswruquok0-jpg.97950/)
![DSCN0760_zpshllo941n.jpg DSCN0760_zpshllo941n.jpg](https://www.landcruiserclub.net/community/attachments/dscn0760_zpshllo941n-jpg.97951/)
![DSCN0761_zpsdyzgq8ie.jpg DSCN0761_zpsdyzgq8ie.jpg](https://www.landcruiserclub.net/community/attachments/dscn0761_zpsdyzgq8ie-jpg.97952/)
Cardboard template next for the wings.
![DSCN0762_zpso3i0bjr2.jpg DSCN0762_zpso3i0bjr2.jpg](https://www.landcruiserclub.net/community/attachments/dscn0762_zpso3i0bjr2-jpg.97953/)
Ended up taking a bit more off the template and then cut some 3mm sheet steel and tacked it on.
![DSCN0763_zpsym3mzm1t.jpg DSCN0763_zpsym3mzm1t.jpg](https://www.landcruiserclub.net/community/attachments/dscn0763_zpsym3mzm1t-jpg.97954/)
![DSCN0764_zpsuzqtsrxe.jpg DSCN0764_zpsuzqtsrxe.jpg](https://www.landcruiserclub.net/community/attachments/dscn0764_zpsuzqtsrxe-jpg.97955/)
![DSCN0766_zpsbaifjgmc.jpg DSCN0766_zpsbaifjgmc.jpg](https://www.landcruiserclub.net/community/attachments/dscn0766_zpsbaifjgmc-jpg.97956/)
Next template.
![DSCN0767_zpswyqjxmjg.jpg DSCN0767_zpswyqjxmjg.jpg](https://www.landcruiserclub.net/community/attachments/dscn0767_zpswyqjxmjg-jpg.97957/)
Cut and tacked in position.
![DSCN0768_zpspg2wplzr.jpg DSCN0768_zpspg2wplzr.jpg](https://www.landcruiserclub.net/community/attachments/dscn0768_zpspg2wplzr-jpg.97958/)
![DSCN0769_zpszbjeop46.jpg DSCN0769_zpszbjeop46.jpg](https://www.landcruiserclub.net/community/attachments/dscn0769_zpszbjeop46-jpg.97959/)
Other side.
![DSCN0771_zpsbohgsqwl.jpg DSCN0771_zpsbohgsqwl.jpg](https://www.landcruiserclub.net/community/attachments/dscn0771_zpsbohgsqwl-jpg.97960/)
![DSCN0772_zpsi21nktu9.jpg DSCN0772_zpsi21nktu9.jpg](https://www.landcruiserclub.net/community/attachments/dscn0772_zpsi21nktu9-jpg.97961/)
![DSCN0774_zpsj46ygde4.jpg DSCN0774_zpsj46ygde4.jpg](https://www.landcruiserclub.net/community/attachments/dscn0774_zpsj46ygde4-jpg.97962/)
End sections.
![DSCN0775_zpshmqdgcjc.jpg DSCN0775_zpshmqdgcjc.jpg](https://www.landcruiserclub.net/community/attachments/dscn0775_zpshmqdgcjc-jpg.97963/)
![DSCN0776_zpsj4pwhhbc.jpg DSCN0776_zpsj4pwhhbc.jpg](https://www.landcruiserclub.net/community/attachments/dscn0776_zpsj4pwhhbc-jpg.97964/)
![DSCN0777_zpsu9tgeiph.jpg DSCN0777_zpsu9tgeiph.jpg](https://www.landcruiserclub.net/community/attachments/dscn0777_zpsu9tgeiph-jpg.97965/)
Decided to add a solid back section, not something you would normally have on a winch bumper, but then this isnt a normal winch bumper with it being mounted so far forward from the cab and me wanting it to be very strong.
![DSCN0779_zpshof9dsxi.jpg DSCN0779_zpshof9dsxi.jpg](https://www.landcruiserclub.net/community/attachments/dscn0779_zpshof9dsxi-jpg.97966/)
![DSCN0781_zps8uv03lx0.jpg DSCN0781_zps8uv03lx0.jpg](https://www.landcruiserclub.net/community/attachments/dscn0781_zps8uv03lx0-jpg.97967/)
![DSCN0782_zpsxrjuj1ad.jpg DSCN0782_zpsxrjuj1ad.jpg](https://www.landcruiserclub.net/community/attachments/dscn0782_zpsxrjuj1ad-jpg.97968/)
![DSCN0783_zpskfduqbkd.jpg DSCN0783_zpskfduqbkd.jpg](https://www.landcruiserclub.net/community/attachments/dscn0783_zpskfduqbkd-jpg.97969/)
Fully welded around the top.
![DSCN0785_zpsskolsaia.jpg DSCN0785_zpsskolsaia.jpg](https://www.landcruiserclub.net/community/attachments/dscn0785_zpsskolsaia-jpg.97970/)
![DSCN0786_zpswwqgugvj.jpg DSCN0786_zpswwqgugvj.jpg](https://www.landcruiserclub.net/community/attachments/dscn0786_zpswwqgugvj-jpg.97971/)
I wanted to add some tube next. 2" would have been far too small so I opted for 3".
Sadly we cant bend 3" in our bender so I only had one option which was to cut and shut some narrow hoops we already had left over from Vitara winch bumpers.
![DSCN0788_zpsxjr7gbrj.jpg DSCN0788_zpsxjr7gbrj.jpg](https://www.landcruiserclub.net/community/attachments/dscn0788_zpsxjr7gbrj-jpg.97972/)
![DSCN0790_zpscszwoc87.jpg DSCN0790_zpscszwoc87.jpg](https://www.landcruiserclub.net/community/attachments/dscn0790_zpscszwoc87-jpg.97973/)
Used some big angle to help keep it all alined while I TIG welded it.
![DSCN0792_zpsmdrrqtt5.jpg DSCN0792_zpsmdrrqtt5.jpg](https://www.landcruiserclub.net/community/attachments/dscn0792_zpsmdrrqtt5-jpg.97974/)
![DSCN0793_zpsxgr0uvoo.jpg DSCN0793_zpsxgr0uvoo.jpg](https://www.landcruiserclub.net/community/attachments/dscn0793_zpsxgr0uvoo-jpg.97975/)
Went for a 1.6mm gap as having them fitted tight would have effectively meant when I ground the weld down afterwards I would have ground all the reinforcement away and it would have been pretty weak.
![DSCN0794_zpsjmtqszzk.jpg DSCN0794_zpsjmtqszzk.jpg](https://www.landcruiserclub.net/community/attachments/dscn0794_zpsjmtqszzk-jpg.97976/)
![DSCN0798_zpsu4bt5xuy.jpg DSCN0798_zpsu4bt5xuy.jpg](https://www.landcruiserclub.net/community/attachments/dscn0798_zpsu4bt5xuy-jpg.97977/)
Ground the welds down.
![DSCN0799_zpszqlk9ab9.jpg DSCN0799_zpszqlk9ab9.jpg](https://www.landcruiserclub.net/community/attachments/dscn0799_zpszqlk9ab9-jpg.97978/)
![DSCN0800_zpsma0ra6jm.jpg DSCN0800_zpsma0ra6jm.jpg](https://www.landcruiserclub.net/community/attachments/dscn0800_zpsma0ra6jm-jpg.97979/)
Cut 10mm to nothing off the bottom of both sides of the hoop to lean it forward slightly away from the tilting cab.
![DSCN0801_zps1fdwyx43.jpg DSCN0801_zps1fdwyx43.jpg](https://www.landcruiserclub.net/community/attachments/dscn0801_zps1fdwyx43-jpg.97980/)
![DSCN0802_zpsktyifhjq.jpg DSCN0802_zpsktyifhjq.jpg](https://www.landcruiserclub.net/community/attachments/dscn0802_zpsktyifhjq-jpg.97981/)
![DSCN0803_zpsubjg97zx.jpg DSCN0803_zpsubjg97zx.jpg](https://www.landcruiserclub.net/community/attachments/dscn0803_zpsubjg97zx-jpg.97982/)
Decided to add a light-bar next so I grabbed one out of the show room.
![DSCN0805_zpsmpqpdkgu.jpg DSCN0805_zpsmpqpdkgu.jpg](https://www.landcruiserclub.net/community/attachments/dscn0805_zpsmpqpdkgu-jpg.97983/)
![DSCN0806_zpshvbjgizv.jpg DSCN0806_zpshvbjgizv.jpg](https://www.landcruiserclub.net/community/attachments/dscn0806_zpshvbjgizv-jpg.97984/)
Welded some brackets onto the hoop for the light-bar, ground the welds down along the top of the winch bumper and then welded the hoop on.
![DSCN0810_zpsduvwl5u8.jpg DSCN0810_zpsduvwl5u8.jpg](https://www.landcruiserclub.net/community/attachments/dscn0810_zpsduvwl5u8-jpg.97985/)
![DSCN0811_zpsulltv2mp.jpg DSCN0811_zpsulltv2mp.jpg](https://www.landcruiserclub.net/community/attachments/dscn0811_zpsulltv2mp-jpg.97986/)
![DSCN0812_zpspnslmxmt.jpg DSCN0812_zpspnslmxmt.jpg](https://www.landcruiserclub.net/community/attachments/dscn0812_zpspnslmxmt-jpg.97987/)
![DSCN0814_zpsix4nax0s.jpg DSCN0814_zpsix4nax0s.jpg](https://www.landcruiserclub.net/community/attachments/dscn0814_zpsix4nax0s-jpg.97988/)
Removed the bumper.
![DSCN0822_zpseu6jbmkh.jpg DSCN0822_zpseu6jbmkh.jpg](https://www.landcruiserclub.net/community/attachments/dscn0822_zpseu6jbmkh-jpg.97989/)
Removed the winch and light-bar and made a start fully welding it all.
![DSCN0823_zpsbe5fb01p.jpg DSCN0823_zpsbe5fb01p.jpg](https://www.landcruiserclub.net/community/attachments/dscn0823_zpsbe5fb01p-jpg.97990/)
![DSCN0824_zpszftokn1a.jpg DSCN0824_zpszftokn1a.jpg](https://www.landcruiserclub.net/community/attachments/dscn0824_zpszftokn1a-jpg.97991/)
Decided to add a reciever hitch so that a front recovery point can be slid in for either snatch recoveries and/or an anchor point for the winch when using a snatch block. It will also be useful for moving big trailers around with a towball slid in.
![DSCN0825_zps4zeum2np.jpg DSCN0825_zps4zeum2np.jpg](https://www.landcruiserclub.net/community/attachments/dscn0825_zps4zeum2np-jpg.97992/)
Put 2 cuts in with the angle grinder then joined them up with the oxy torch.
![DSCN0826_zpskuizgun8.jpg DSCN0826_zpskuizgun8.jpg](https://www.landcruiserclub.net/community/attachments/dscn0826_zpskuizgun8-jpg.97993/)
![DSCN0827_zpsnuh4zejt.jpg DSCN0827_zpsnuh4zejt.jpg](https://www.landcruiserclub.net/community/attachments/dscn0827_zpsnuh4zejt-jpg.97994/)
Cleaned it up with the finger linisher.
![DSCN0828_zpsnjlcw2gy.jpg DSCN0828_zpsnjlcw2gy.jpg](https://www.landcruiserclub.net/community/attachments/dscn0828_zpsnjlcw2gy-jpg.97995/)
I wasnt able to use a conventional receiver hitch pin as it will be tricky to get to the other side to get the R clip in and out. So I picked up an M16 bolt instead and I will weld a wing-nut style wing to the bolt head.
![DSCN0829_zpsmb0glzsx.jpg DSCN0829_zpsmb0glzsx.jpg](https://www.landcruiserclub.net/community/attachments/dscn0829_zpsmb0glzsx-jpg.97996/)
![DSCN0830_zpsx0qqssn1.jpg DSCN0830_zpsx0qqssn1.jpg](https://www.landcruiserclub.net/community/attachments/dscn0830_zpsx0qqssn1-jpg.97997/)
Welded the nut on to create a captive nut.
![DSCN0831_zpsxfka6ldv.jpg DSCN0831_zpsxfka6ldv.jpg](https://www.landcruiserclub.net/community/attachments/dscn0831_zpsxfka6ldv-jpg.97998/)
Still need to weld it in position but it will sit like this.
![DSCN0835_zpsfcpkbsla.jpg DSCN0835_zpsfcpkbsla.jpg](https://www.landcruiserclub.net/community/attachments/dscn0835_zpsfcpkbsla-jpg.97999/)
![DSCN0836_zpsms6uydek.jpg DSCN0836_zpsms6uydek.jpg](https://www.landcruiserclub.net/community/attachments/dscn0836_zpsms6uydek-jpg.98000/)
In preparation for the re-spray we got the sides of the pick up bed shotblast.
![DSCN0815_zpsyg5jfqgc.jpg DSCN0815_zpsyg5jfqgc.jpg](https://www.landcruiserclub.net/community/attachments/dscn0815_zpsyg5jfqgc-jpg.98001/)
![DSCN0816_zpsozt2ugic.jpg DSCN0816_zpsozt2ugic.jpg](https://www.landcruiserclub.net/community/attachments/dscn0816_zpsozt2ugic-jpg.98002/)
![DSCN0821_zps72wnubvc.jpg DSCN0821_zps72wnubvc.jpg](https://www.landcruiserclub.net/community/attachments/dscn0821_zps72wnubvc-jpg.98003/)
And thats as far as I got!
I need to finish the bumper and get it powdercoated and re-fitted. We've ordered 6 mud tyres to hopefully stop the 2wd (well technically its a 4wd, as theres 4 tyres on the driven rear axle) Dyna from getting stuck in the fields (padocks as there called here).
The new tyres will be mounted on the original wheels which we will get shotblast and powdercoated.
Then theres the re-spray/paint work to do.
The drivers seat has just come from back from being repaired and re-upholstered and looks great.
The engine has also had a bit of work done on the cooling system which was all pretty rotten.
So a bit more work and then it can go off and have some fun with the excavator! It will come in very handy when my boss starts building the mote around his farm house!![Dance :dance: :dance:](/custom/images/smilies/pack2/eusa/dance.gif)
We need to get back on the airboat project and get the propeller ordered from the states.
The huge gum tree should have been cut down by now ready for me to build the big 3 storey tree house for it, which will be built in pre-fabricated sections at work and then taken to the farm, lifted up into the tree and bolted together.![Thinking :think: :think:](/custom/images/smilies/pack2/eusa/think.gif)
I've also got a tiny bit more work to do on the solar car for next months Simpson Desert crossing.![Cool :icon-cool: :icon-cool:](/custom/images/smilies/pack2/icon/cool.gif)
In the mean time I've picked up more supplies and my entire weekend will be spent practicing welding pieces of pipe, Again!
This is what I've been getting through every week!![Rolling Eyes :icon-rolleyes: :icon-rolleyes:](/custom/images/smilies/pack2/icon/rolleyes.gif)
![DSCN0795_zpsa6itr5tx.jpg DSCN0795_zpsa6itr5tx.jpg](https://www.landcruiserclub.net/community/attachments/dscn0795_zpsa6itr5tx-jpg.98004/)
A $50 bottle of argon.
![DSCN0796_zpsau39ztyb.jpg DSCN0796_zpsau39ztyb.jpg](https://www.landcruiserclub.net/community/attachments/dscn0796_zpsau39ztyb-jpg.98005/)
And a crate full of machined pipe and filler rod.
![DSCN0797_zpsokvejpuv.jpg DSCN0797_zpsokvejpuv.jpg](https://www.landcruiserclub.net/community/attachments/dscn0797_zpsokvejpuv-jpg.98006/)
The big test is 2 weeks tomorrow so I'm practicing like crazy!![Smile :icon-smile: :icon-smile:](/custom/images/smilies/pack2/icon/smile.gif)
Hoping the Sunday after the test I can finally get back on with LJ!![Thumbup :thumbup: :thumbup:](/custom/images/smilies/pack2/icon_thumbup.gif)
I had another busy week at work, only a short one as Monday was a public holiday as it was the Queens birthday.
I've been busy working on my bosses latest toy, his tip truck.
I needed to replace the rotten front cross member and build a new front bumper with a big 12,000LB winch mounted in it.
The rotten cross member was riveted in position so I had to grind the heads off the rivets and punch them out.
I ended up having to slice it down the middle to get it off.
Cut some 90mm x 10mm flat to length and ground the corners off 2 edges to fit snugly in the chassis rails, this would give me something nice and strong to mount the winch off.
Drilled some holes in it to line up with existing holes in the chassis.
Bolted in position.
Cut and drilled some 75mm x 50mm angle to replace the rotten chassis cross member.
Cut and drilled another for the bottom.
Used the oxyacetylene torch to notch out the 90mm flat to allow the winch to sit lower.
With no machine big enough to cut the 200mm x 6mm flat I needed to use for the winch to bolt to, I clamped a straight edge to it and cut it with the 9" grinder.
Drilled it for the winch and ground the mill scale off where I intended on welding.
Prepared the 90mm flat for welding by beveling the edges to ensure good weld root penetration.
Used the trolley jack to lift the piece of 200mm flat up into position and bolted it to the bottom of the winch and tack welded the 200mm to the 90mm.
Front section next, again out of the 200mm x 6mm.
Marked and drilled.
Joined the holes up with the grinder.
The fairlead bolts through the 6mm into the winch. This would mean the winch will be bolted in position with 4 bolts coming up from the base and 2 through the front so should be nice and strong.
Bolted it on and tack welded the 200mm front to the rest of the winch mount.
The winch had to be mounted quite far forward to clear the tilting cab.
Cardboard template next for the wings.
Ended up taking a bit more off the template and then cut some 3mm sheet steel and tacked it on.
Next template.
Cut and tacked in position.
Other side.
End sections.
Decided to add a solid back section, not something you would normally have on a winch bumper, but then this isnt a normal winch bumper with it being mounted so far forward from the cab and me wanting it to be very strong.
Fully welded around the top.
I wanted to add some tube next. 2" would have been far too small so I opted for 3".
Sadly we cant bend 3" in our bender so I only had one option which was to cut and shut some narrow hoops we already had left over from Vitara winch bumpers.
Used some big angle to help keep it all alined while I TIG welded it.
Went for a 1.6mm gap as having them fitted tight would have effectively meant when I ground the weld down afterwards I would have ground all the reinforcement away and it would have been pretty weak.
Ground the welds down.
Cut 10mm to nothing off the bottom of both sides of the hoop to lean it forward slightly away from the tilting cab.
Decided to add a light-bar next so I grabbed one out of the show room.
Welded some brackets onto the hoop for the light-bar, ground the welds down along the top of the winch bumper and then welded the hoop on.
Removed the bumper.
Removed the winch and light-bar and made a start fully welding it all.
Decided to add a reciever hitch so that a front recovery point can be slid in for either snatch recoveries and/or an anchor point for the winch when using a snatch block. It will also be useful for moving big trailers around with a towball slid in.
Put 2 cuts in with the angle grinder then joined them up with the oxy torch.
Cleaned it up with the finger linisher.
I wasnt able to use a conventional receiver hitch pin as it will be tricky to get to the other side to get the R clip in and out. So I picked up an M16 bolt instead and I will weld a wing-nut style wing to the bolt head.
Welded the nut on to create a captive nut.
Still need to weld it in position but it will sit like this.
In preparation for the re-spray we got the sides of the pick up bed shotblast.
And thats as far as I got!
I need to finish the bumper and get it powdercoated and re-fitted. We've ordered 6 mud tyres to hopefully stop the 2wd (well technically its a 4wd, as theres 4 tyres on the driven rear axle) Dyna from getting stuck in the fields (padocks as there called here).
The new tyres will be mounted on the original wheels which we will get shotblast and powdercoated.
Then theres the re-spray/paint work to do.
The drivers seat has just come from back from being repaired and re-upholstered and looks great.
The engine has also had a bit of work done on the cooling system which was all pretty rotten.
So a bit more work and then it can go off and have some fun with the excavator! It will come in very handy when my boss starts building the mote around his farm house!
![Dance :dance: :dance:](/custom/images/smilies/pack2/eusa/dance.gif)
We need to get back on the airboat project and get the propeller ordered from the states.
The huge gum tree should have been cut down by now ready for me to build the big 3 storey tree house for it, which will be built in pre-fabricated sections at work and then taken to the farm, lifted up into the tree and bolted together.
![Thinking :think: :think:](/custom/images/smilies/pack2/eusa/think.gif)
I've also got a tiny bit more work to do on the solar car for next months Simpson Desert crossing.
![Cool :icon-cool: :icon-cool:](/custom/images/smilies/pack2/icon/cool.gif)
In the mean time I've picked up more supplies and my entire weekend will be spent practicing welding pieces of pipe, Again!
This is what I've been getting through every week!
![Rolling Eyes :icon-rolleyes: :icon-rolleyes:](/custom/images/smilies/pack2/icon/rolleyes.gif)
A $50 bottle of argon.
And a crate full of machined pipe and filler rod.
The big test is 2 weeks tomorrow so I'm practicing like crazy!
![Smile :icon-smile: :icon-smile:](/custom/images/smilies/pack2/icon/smile.gif)
Hoping the Sunday after the test I can finally get back on with LJ!
![Thumbup :thumbup: :thumbup:](/custom/images/smilies/pack2/icon_thumbup.gif)
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