Warn 9500i Winch in ARB Bumper

Discussion in 'How To' started by 65Corvair, Nov 14, 2020.

  1. 65Corvair

    65Corvair Member

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    Over the summer I picked up a Warn 9500i winch for cheap from a local ad. Then a few weeks later I found a used ARB bumper with in driving distance.

    Natively, a 9500i will not fit the ARB. It is too tall and would mount in the wrong orientation for the ARB.

    The bumper was is pretty rough shape when I got it, and knowing I had to modify it to make it work only has made this project more fun.

    It came with the original mounting hardware, but some were stripped out and others has broken bolts stuck in the weld nuts. So I made my own from some 1.5 inch by 3/16 angle iron.

    Note: I am by no means a professional welder.

    [​IMG]

    The winch came with a 1/4 inch winch plate that just perfectly fit between the "rails" of the bumper mount. With some more angle iron supports below, and welding it all the way around, it is quite sturdy.
    I essentially made Detours USA Backbone out of the ARB bumper mount.

    [​IMG]

    The outer shell needed quite a bit of work because all of the layers in the front section and grew over a half inch from all the rust jacking. I cut out a large section of the front an replaced it with an 1/8 plate.
    Since the outer shell will only be holding the fairlead, it doesn't need anywhere as much reinforcement.

    [​IMG]

    Here is the bumper rough mounted to the Jeep. Lots more work to do yet.

    [​IMG]
     
  2. 65Corvair

    65Corvair Member

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    The bumper didn't come with the ARB turn signals, and I really didn't care for how they looked, so I enlarged the cutouts to accept a standard 6 inch oval light.

    [​IMG]

    As you can see there is quite a bit of pitting, This will be filled in and painted over at the end.
    Next on the list is to cut out some clearance for the winch engagement lever.

    [​IMG]
     
    LibertyTC likes this.
  3. tommudd

    tommudd Moderator Staff Member Moderator

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    Looks like an 02-04 bumper on an 05-07

    Did they park that bumper nose down in the ocean or what?
    Looks of rust for sure
     
  4. 65Corvair

    65Corvair Member

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    It is a 05-07 bumper, the 02-04 bumpers have the wrap around turn signals that came with the Liberty in stock form, and the larger fog lights. I actually have a 02-04 bumper too, but it doesn’t work well on a 05-07. The biggest issue is that there is too much gap between the top of the bumper and the fender flares.
     
  5. tommudd

    tommudd Moderator Staff Member Moderator

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    Earlier ones yes, but the 05-07s I have seen do not cover the fog light holes
    I too have had a 02-4 , had it for 12 years and mounted 5 other ARBs on bot early and later models of KJs
     
  6. 65Corvair

    65Corvair Member

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    Cut out a section for the engagement lever for the winch.

    [​IMG]
     
  7. 65Corvair

    65Corvair Member

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    Cut out the fairlead opening for the winch and sanded/primed the hoop

    [​IMG]
     
  8. 65Corvair

    65Corvair Member

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    Smeared some bondo body filler in the rust pits to make it look presentable after painting.
    I have never used it before, so we shall see how this goes.

    [​IMG]