Custom hidden winch mount

[Adrian D]

More progress. Still needs a bit of trimming before it will sit flat on the frame rails. And based on measurements I have a good hope that the top of the inch plate will sit as high as the top of the factory crossmember. It would be an added bonus, as I would not have to cut and re-weld bracketry.

Cutting the crossmember went too easy, a little over an hour from taking off the grille to taking out the crossmember.



These are the tie-in plates to give it more strength in the are where it joins to the framerail:







Thoughts on it strength-wise?

I noticed the factory us-spec overland hooks are mounted with 10.9 hardware, so that's exactly what I will get for the winch install. And I will have to add some brackets to be able to use the third mounting point for the factory tow hooks.

[Adrian D]

The headlight support is just temporarily in place:




The bumper needs a bit more trimming and I will have to get some sort of cover over the rope


Next up, overland hook support legs.

[Adrian D]

Criticism is welcome, I'm aware my welds don't look awesome so even tips on how to improve are welcome

After wasting one hour driving across town and being sold 8.8 bolts instead of 10.9 like I asked, I found fine threaded 10.9 bolts and nuts with collar online. Going to use 10.9 for the winch too, because why not, at $2 for 4 bolts...

And I found this idea to cover the winch rope:




I wonder if I can coax my wife into sewing this

[Adrian D]

Hook support are done:


And I weighed everything:
Factory crossmember: 5kg
Winch plate: 7.5kg
Winch: 16.5kg
Solenoid box: 1kg

With the hawse, the total is under 21kg added to the front of the car.

It's all been painted during the weekend, so final install and wiring is next.

[Adrian D]

So, I've figured out why my welds are brown and why they have more spatter than what I see online....it's the fact that I use 100% CO2 as shielding gas. Too much wire speed might also contribute to the spatter.

Still figuring out the settings of this ancient german MIG welder...

[Adrian D]

All 10.9 hardware, fine threaded:






Still needs 2 small spacers for the side mounts to the framerails and then I can finish the install.

The hawse is recessed into the bumper, so I'm keeping the license plate holder and will remove the plate when offroading.
I think I can keep most of the foam behind the bumper, for impact protection.

Positive wire is well secured. The wires from the wireless receiver go through a sealed plug (so that I can change the receiver just in case). Ground goes to the battery terminal and I hope it won't cause a weird ground loop.

[Adrian D]

Aaand it's done.
I drilled a tiny hole in the bumper where I can stick a 1/4" drive screwdriver for the clutch:


Waxed:



Bumper on for the last time (hopefully)