beatupjeep
03-15-2015, 04:20 PM
Parts:
-I used a harbor freight winch mount plate which goes for about $50.
http://www.harborfreight.com/universal-channel-winch-mount-90476.html
You could just make this out of steel plate or U-channel though, so lets say it costs $10 in material.
-5" leg, 3/8" thick, about 10" long piece of steel angle iron "L" shape. I got 48" worth for $10 at my local scrap yard. To do it exactly the way I did it, you make two 5" long brackets..so thats 10" total.
-factory XJ front tow hook bracketry. I got a set at my local pick and pull for around $25.
-Various quality (10.9 grade or equivalent) hardware..probably $5 if you get it at the junkyard. You need about qty 8 of at least M12 x around 40mm long I think with nuts and washers.
-Brain. Im not putting every little detail in here. But you are just making two 3/8" L brackets and welding them to the stock jeep tow brackets, then adding holes as needed for all the bolts. Critical parts are putting the holes in the right places, doing high quality welds, making sure all the mating surfaces are flat and burr free, and making sure everything lines up right.
Tools:
Drill press is nice because you will have to drill some around 1/2" dia holes in steel, I suppose a high quality hand drill could work.
Transfer punches, auto center punch, and pointy center drill are what I used to get all the holes marked out in the right spots.
Welder to weld the 3/8" angle iron to the stock XJ tow hook bracket.
The usual sockets/wrenches/ratchets, etc..plus some torx bits for the bumper. I got a set of 5 (or 6?) that included T50 and T55 for $10 at autozone.
Bandsaw to cut the angle iron or possibly a hacksaw or sawzall if you are really slumming it. Or get the scrap yard to cut the pieces for you.
Theory of operation (lol)
You are just making two "L" shaped brackets and welding them to the stock XJ tow hook brackets that go on the FRONT of the cross member (see pics).
Your new brackets then pop up over the stock bumper. You can slide the bumper bracketry around to make room.
Holes need to be drilled in the new brackets and the winch mount so it all bolts together. Also in the new brackets to allow the bolts that mounted the brackets you welded onto to mount to the Jeep.
Now, I could have just done this with one long "bracket" instead of making two little ones, and it would have been much stronger and stiffer. But whatever I wanted less weight and I think these are plenty strong.
I think the stock approach angle was pretty much maintained here.
Something I may have overlooked is having enough clearance BEHIND the winch..right now any cable loops on the back of the winch will hit the grill. Im not worried so much cosmetically as much as functionally. I want the winch to be easy to use.
The hardware I have on there is just temporary until I go buy the good stuff.
The picture with the bumper off only shows the passenger bracket installed.
Thoughts? I'm looking for criticism! I have never used a winch or done any recovery with the Jeep. If you think this is a recipe for disaster I'd like to know why.
http://i242.photobucket.com/albums/ff197/acannell/20150315_135908_zps3cjdclu1.jpg (http://s242.photobucket.com/user/acannell/media/20150315_135908_zps3cjdclu1.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150315_135917_zpsl8yf1yuu.jpg (http://s242.photobucket.com/user/acannell/media/20150315_135917_zpsl8yf1yuu.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150315_135928_zps2gnglia7.jpg (http://s242.photobucket.com/user/acannell/media/20150315_135928_zps2gnglia7.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150315_135949_zpso4ww3msx.jpg (http://s242.photobucket.com/user/acannell/media/20150315_135949_zpso4ww3msx.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150315_140013_zpsviwdfpce.jpg (http://s242.photobucket.com/user/acannell/media/20150315_140013_zpsviwdfpce.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150312_140225_zpsrao8f5qe.jpg (http://s242.photobucket.com/user/acannell/media/20150312_140225_zpsrao8f5qe.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150312_140230_zpsclfe7usy.jpg (http://s242.photobucket.com/user/acannell/media/20150312_140230_zpsclfe7usy.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150312_150523_zps8f4luwsw.jpg (http://s242.photobucket.com/user/acannell/media/20150312_150523_zps8f4luwsw.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150312_150544_zpsmxodmdui.jpg (http://s242.photobucket.com/user/acannell/media/20150312_150544_zpsmxodmdui.jpg.html)
-I used a harbor freight winch mount plate which goes for about $50.
http://www.harborfreight.com/universal-channel-winch-mount-90476.html
You could just make this out of steel plate or U-channel though, so lets say it costs $10 in material.
-5" leg, 3/8" thick, about 10" long piece of steel angle iron "L" shape. I got 48" worth for $10 at my local scrap yard. To do it exactly the way I did it, you make two 5" long brackets..so thats 10" total.
-factory XJ front tow hook bracketry. I got a set at my local pick and pull for around $25.
-Various quality (10.9 grade or equivalent) hardware..probably $5 if you get it at the junkyard. You need about qty 8 of at least M12 x around 40mm long I think with nuts and washers.
-Brain. Im not putting every little detail in here. But you are just making two 3/8" L brackets and welding them to the stock jeep tow brackets, then adding holes as needed for all the bolts. Critical parts are putting the holes in the right places, doing high quality welds, making sure all the mating surfaces are flat and burr free, and making sure everything lines up right.
Tools:
Drill press is nice because you will have to drill some around 1/2" dia holes in steel, I suppose a high quality hand drill could work.
Transfer punches, auto center punch, and pointy center drill are what I used to get all the holes marked out in the right spots.
Welder to weld the 3/8" angle iron to the stock XJ tow hook bracket.
The usual sockets/wrenches/ratchets, etc..plus some torx bits for the bumper. I got a set of 5 (or 6?) that included T50 and T55 for $10 at autozone.
Bandsaw to cut the angle iron or possibly a hacksaw or sawzall if you are really slumming it. Or get the scrap yard to cut the pieces for you.
Theory of operation (lol)
You are just making two "L" shaped brackets and welding them to the stock XJ tow hook brackets that go on the FRONT of the cross member (see pics).
Your new brackets then pop up over the stock bumper. You can slide the bumper bracketry around to make room.
Holes need to be drilled in the new brackets and the winch mount so it all bolts together. Also in the new brackets to allow the bolts that mounted the brackets you welded onto to mount to the Jeep.
Now, I could have just done this with one long "bracket" instead of making two little ones, and it would have been much stronger and stiffer. But whatever I wanted less weight and I think these are plenty strong.
I think the stock approach angle was pretty much maintained here.
Something I may have overlooked is having enough clearance BEHIND the winch..right now any cable loops on the back of the winch will hit the grill. Im not worried so much cosmetically as much as functionally. I want the winch to be easy to use.
The hardware I have on there is just temporary until I go buy the good stuff.
The picture with the bumper off only shows the passenger bracket installed.
Thoughts? I'm looking for criticism! I have never used a winch or done any recovery with the Jeep. If you think this is a recipe for disaster I'd like to know why.
http://i242.photobucket.com/albums/ff197/acannell/20150315_135908_zps3cjdclu1.jpg (http://s242.photobucket.com/user/acannell/media/20150315_135908_zps3cjdclu1.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150315_135917_zpsl8yf1yuu.jpg (http://s242.photobucket.com/user/acannell/media/20150315_135917_zpsl8yf1yuu.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150315_135928_zps2gnglia7.jpg (http://s242.photobucket.com/user/acannell/media/20150315_135928_zps2gnglia7.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150315_135949_zpso4ww3msx.jpg (http://s242.photobucket.com/user/acannell/media/20150315_135949_zpso4ww3msx.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150315_140013_zpsviwdfpce.jpg (http://s242.photobucket.com/user/acannell/media/20150315_140013_zpsviwdfpce.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150312_140225_zpsrao8f5qe.jpg (http://s242.photobucket.com/user/acannell/media/20150312_140225_zpsrao8f5qe.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150312_140230_zpsclfe7usy.jpg (http://s242.photobucket.com/user/acannell/media/20150312_140230_zpsclfe7usy.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150312_150523_zps8f4luwsw.jpg (http://s242.photobucket.com/user/acannell/media/20150312_150523_zps8f4luwsw.jpg.html)
http://i242.photobucket.com/albums/ff197/acannell/20150312_150544_zpsmxodmdui.jpg (http://s242.photobucket.com/user/acannell/media/20150312_150544_zpsmxodmdui.jpg.html)