HOW TO: Install a Warn 9500 XP in an OEM bumper (cUstom mount)

[m_volyrakis]

HOW TO: Install a Warn 9500 XP in an OEM bumper (custom mount) UPDATED

WINCH PLATE:

Started off with removing the bumper, strapping the winch on

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and making a rough mock up of what I had in mind.

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I then made an AutoCad template

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and a prototype out of tin.

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Fitted it on my rig a couple of times and re measured again and again and again...:freak3: and then measured some more.
Calculated everything 5-6 times and made numerous changes to the AutoCad Template...

and finally made one out of 1/4 inch steel.

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After some refitting and recalculating and trimming.... I ended up with this:

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One more try..

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Reinforced sanded galvanized and electrostaticly painted... I can't wait!!!

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last test round..

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Some minor bumper trimming

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Drilled trough for some extra support

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Almost done..

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SOLENOID PACK

Got this empty spot in my engine bay and decided to mount the solenoid pack using that hole in the middle

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Made a 1/4 thick bracket which I measured multiple timew but managed to get the size and orientation wrong... so i had to shave a bit off.

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Mounted the pack

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and the remote

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THE FINAL PRODUCT:

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Thanks to Speedracerbubba who has been a GREAT HELP
I'm having an Amsteel Blue synthetic winch line 5/16 X 100 ft delivered to me!

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Will post a couple of shots when the job is done!


So, what do you think?



Cable came in a couple of days ago thanks to SPEEDRACERDUBBA!! :head3::favorites37::roflbow::happy107:

Amsteel Blue Winch Rope Line 5/16" x 100' w/ crush proof thimble

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Installed the same day

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BUT..... there is always a catch...

The crush proof thimble which I so much desired is too thick to fit in the Warn hook
kopkrab.gif(banghead)(censored)(censored) (censored)(Argh):mad3::mad3::mad3::mad3: :wtf2::wtf2::disgust: :Frustrated::Frustrated::Frustrated::icon_sad: cryinghard.gifcryinghard.gifcryinghard.gif cryinghard.gif

So this is the only solution I could come up with to have the thing installed..

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Any Ideas? :Stupid Me: Please:help:

 

[JeepINgeek]

That is AWESOME!

mind sharing that cad template?

Though im not sure my xd9000i would work in that situation its worth looking into!

 

[mag03kj]

Man that looks great!

 

[speedracerbubba]

That's great but we want to see the speaker amplifiers installed! Lol

Again, very impressive and unique, Michalis!

I can't wait for the last box to get to you so we can see it with the pretty winch line.

 

[ptsb5a]

Michalis, that's freaking georgeous man. Great job. Now go and produce some and market them. Awesome to see some pioneering spirit alive and well.

 

[ridenby]

That is very cool mount.Just wonder about the strength. Man that is cool though.

 

[m_volyrakis]

mind sharing that cad template?

Yes Autocad template is freely available to all. I have taken so much form this community was high time I gave something back.

Just give me some time to make a couple of updates..

Just wonder about the strength. Man that is cool though.

I did a lot of reading before starting the fabrication progress. The plate is 1/4 thick and just to be on the safe side I reinforced each corners with one additional 1/4 plate so the stress points are 2/4 thick.

Plus I run 2 rods at the length of the winch plate just to feel safer in case I need to use the winch to lift the rig vertically. This is also the reason why I chose to position the flair lead outside the number plate

 

[m_volyrakis]

AutoCad is ready! shoot me a PM!

 

[HoosierJeeper]

Looks great! Are you lifted?

 

[m_volyrakis]

OME all around with the 927s for the front end.

 

[jinstall]

I like it alot but I only worry about the strength in actually wenching out of something. I am not knocking your work because I really like it but I only worry about it holding up under usage. Way cool fabrication.

 

[m_volyrakis]

Thank you very much!
I understand your concerns. I'm also concerned.Holding fine... so far....
As I posted before, the main structure is 1/4 thick and the corners are 1/2 thick.
Wish Boiler could chime in and use his experteese to shed some light on the subject


will let the forum know if something changes.

 

[Dave]

Awesome job. When you use it let us know how it does.

Dave

 

[m_volyrakis]

Used it twice so far, first was a test run, pulling my self a few times to see how things work and second was a rescue of a pick up truck that had fallen in a drainage ditch under heavy rain. The guy didn't have any lockers and was stuck with one wheel in the ditch and the apposite rear on the air.

The mount is holding up so far :smokin:

 

[kjweston]

one question... HOW MUCH??

 

[m_volyrakis]

Give or take 140 € that includes the steel plate, cutting bending it to shape, galvanizing and powder coating and a couple of beers

 

[blue_kjR417]

Man that is freakin awesome!!!!!

You should sell that design to the company that makes the backbone for the KJ!

It looks like it came from the factory that way!

I'm not a mechanical engineer like boiler but I am an undergrad studying to be one and I think it would hold better than you think, there may be some weak points but the real test will probably be the bolts you used mounting it to the crossmember.

 

[TruLiberty]

That looks incredible bro...Is it strong enough for a good pull? i would assume so...enough connection points..

 

[m_volyrakis]

8 points in total.:smokin:

 

[KingMick217]

That is some nice work... Great idea too. I was thinking about doing something VERY similiar when I ran acrossed yours. That is awesome. Kudos!