The winch/dual battery project...

[crawler#976]

Parts list:
Warn M8000
100' of Winchline combo w/ Safety Thimble and 3/4" shackle
Winchline Aluminum fairlead
SurePower Isolator and install kit
Blue Orbital deep cycle battery 950CCA
existing Yellow Orbital starting battery 850CCA
10' of red 2 gage cable
15' of black 2 gage cable
(12) 2 gage crimp on terminals and terminal crimper
various wire butt splice and ring terminals in 8, 10, and 14 gage sizes
wire in 8, 10, and 14 gage sizes
1/2" dia heat shrink tubing
3/8" dia heat shrink tubing
1/4" dia heat shrink tubing
TJM-17 bumper shell
6' 1/4" x 1.5" flat stock
6' 1/8" x 2" flat stock
6' 1/8" x 1" angle iron
Lincoln 175
Makita grinders - one with a wheel, the other with a flapper.
1/2 drill w/ various bits and step bits
crappy ACE paint - gonna have to repaint everything when it warms up...

...and large parts of three weekends.

Fabricated parts:
Cruise Control relocation bracket
Battery tray and hold down
Winch Controller bracket

I'm pleased with the results with one exception. Comments/suggestions welcome @

http://expeditionportal.com/forum/showthread.php?t=9965

So, I'm going to have to come up with a front recovery point and addtional bolts for the winch to frame before I consider it 100% complete.

Mark

 

[Willman]

Nice and clean!

Looks good!

 

[p1michaud]

Winch controller mounting.

Fabricated parts:
Winch Controller bracket

I like where you have mounted the winch controller. Do you have any other pictures of the bracket before it was bolted in place. I've got my winch controller in the same location, but standing on it's edge.

Controller location pic 1

Controller location pic 2

Controller location pic 3

I have to revise the mounting bracket, it's not as solid as it could be.

Cheers,
P

 

[crawler#976]

I didn't get a photo of the bracket for the winch controller prior to installing it. It's made from 1/4" strap, uses the existing tapped hole in the frame where the stock battery cable clamp went, and a tapped hole in the fender well for additional support. I'll see if I can get a pic of it in place, but it's really tight in there. In retrospect I could have made the bracket taller for more clearance and an easier install, but as is it's very ridged.

Mark

 

[Ursidae69]

Nice work Mark!

 

[crawler#976]

...Do you have any other pictures of the bracket before it was bolted in place.

Well, this is as close to out as it'll be for a while. I had to move it to install upper A-Arms...

The lower leg is about 3" long and attach's where the battery cable tie down was in the frame. The small attachment point on the side uses a tapped hole on the fender well. The upper leg is 90 degs to the frame and has a 3/8 piece of angle iron as a brace. The length of the leg is roughly the width of the control box. It is very ridged.

 

[p1michaud]

Pictures

Well, this is as close to out as it'll be for a while. I had to move it to install upper A-Arms...

The lower leg is about 3" long and attach's where the battery cable tie down was in the frame. The small attachment point on the side uses a tapped hole on the fender well. The upper leg is 90 degs to the frame and has a 3/8 piece of angle iron as a brace. The length of the leg is roughly the width of the control box. It is very ridged.

Thanks for the pictures and description!
Cheers,
P

 

[crawler#976]

It's done!

Well, I pulled off the TJM, removed the winch to make it easier to move, re-installed it and adjusted it back into position. Then it came off, and after a session of wire wheelin', I welded all the parts that are bolted together. It's solid as a rock! Once that was completed, I added a piece of 3/8" stock to the winch mount, welded a 1/4' plate to the top of the frame, drilled two 9/16" holes per side thru the new mount and thru the frame, made and welded in sleeves to reinforce the frame, and installed the winch into the bumper. With everything in place, I got the bumper back on and bolted down with 6 bolts per side, and used the stock tie down brackets for recovery points.

Mark

 

[Cabrito]

Looks real nice Mark - :beer:
I'm in the early planing stages of doing a dual set up for my cruiser to help run all my accessories and a winch someday.

-Michael