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Winch tray install

Trevor

Well-Known Member
Joined
Jul 25, 2010
Messages
1,879
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england
I've wanted a behind bumper winch in the 120 for a while now, so this week I trundled up to North Lincs and spent a couple of days with ChrisGreen90 in his workshop where he was going to fabricate something from scratch.

I was greeted with a nice sight to start the day off right and keep the unit toasty.

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Off with the bumper and front crossmember.

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A bit of work in wood to template up bits and pieces.

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" I said, do you do Liver?" :lol::lol::lol:

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The aircon pipe needed to be moved back nearer to aircon rad, the metal bracket was removed and the clip reused to hold it in place.

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A man's band saw

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Cue the A Team music.

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I had a standard tray which was cut and modified to fit.

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New brackets made to fit the existing bolts on the end of the chassis rail and ready for tacking to the tray.

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I had the job of cutting my own bumper to set the fairlead positioning.

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I forgot to take photos at various stages, largely due to a mixture of excitement from playing with a flappy wheel grinder, MIG welder (Chris corrected my 3" run :icon-redface:) and making the odd brew but eventually this is what we had, including the swivel eye recovery points.

Chris drilling the recovery points.

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This seems to be a common pose while Chris works, maybe it's Hull thing :happy-cheerleaderk:

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So then I got to paint it.

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Then we got to fitting it on the truck.

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There were 2 holes that were perfectly positioned to mount the relay, just needed threading.

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The Champion winch I was originally going to use packed in, so I convinced Mrs Trev to match the Dyneema I'd already bought with a TDS 9.5 Goldfish :dance::dance::dance:

I was going to install the Dyneema through the drum and use the grub screws, I was shown a different way which I thought I would see if it's as good as claimed. Essentially it's a couple of turns on the drum, loop over the incoming rope and splice back in to make a kind of noose, this slides down to the drum and you wind it on. I'm sure there will be some views on this method so let the discussion begin.

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Refit the bumper. Now you see me....

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.... now you don't.

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We ran out of time to fettle in a kill switch, hinge/trim the number plate and mount the wander lead socket but these I can do later. Chris also made up the brackets to fasten the underside of the bumper back to the factory bash plate.

I can't thank Chris enough, not only was it a good couple of days of banter but I was really impressed with the attention to detail, workmanship, problem solving and skill set that Chris has. I'm truly delighted in a bespoke and rugged solution for my truck. Squeezing in this winch into the space available with only a few millimeters to play with takes some doing, top job Chris :thumbup::thumbup::thumbup:.

After driving home and allowing the suspension to settle, the front is now 15mm lower.............springs next year perhaps with suspension to go with it?
 
Nice work guys :)

Sent from my GT-I9100 using Tapatalk
 
Looks like a top job mate, so I'm guessing Chris did 99% of the work...
 
I would say 100%, I was on fire stoking, painting and mostly p**s taking duties.
 
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Looks good - I like things nice and subtle. :thumbup:

Quick question re the the 2 recovery points - would they not bend forwards under load? :think: (Unless I have missed something :oops:)
 
The shaft of the recovery point passes through a hole in the winch mount that is only a couple of mm larger, the wider part of the recovery point stops it from "falling through" so the actual vertical movement is very small. I'll go and measure it tomorrow.

There is a large washer welded to the shaft of the recovery point which is in front of the plate, this allows a little forward/backward movement and hence the ability to rotate.
 
Well that was an interesting couple of days. I really enjoyed fabbing this one up. It is nice to be working on LC's rather than rusty old Landrovers.

Trev was the perfect customer, he knew exactly what he wanted and was prepared to spend the time to have it just so It was a pleasure to work with images.jpg.:lol::lol::lol:

It was a long couple of days and those that know Trev will be amazed that he was lucid ate 7AM.:lol:

Chadr I may be wrong but I think Trev may have missed what you were asking. I assume you are asking if the recovery points will bend the plate under load. Well not they won't. you can't really tell from the first picture below(mainly because they haven't been fitted yet but both uprights are gusseted nearly the full width of the tray and are mounted through 12mm thick steel. The basics of this came from 2 LR bumpers I have built previously that have been well abused with no flexing that I can see.

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You can see the supports better here.
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Thanks Chris - I knew I must have missed something!

I saw the recovery points in the first picture (before paint) and completely missed the gussets/supports in the later (post painted) pic. :thumbup:
 
Top job fellas! I like it a lot. Also you have a great workshop space there Chris!:clap: The sky's the limit mate!:icon-biggrin:
 
That looks good. Slippery slope now Trev ;)
 
lol. Winch is not needed actually with ATRAC ;)
 
Quite right, winch was fitted to assist those less fortunate and ATRAC-less :whistle:
 
Looks great guys. Really neat install.

have you used it yet tho?.....
 
Not for real yet, I did winch another car just to get the dyneema tensioned onto the drum, but now ready and able.
 
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