Winch mounted without winch bar! GU Patrol

Submitted: Thursday, Dec 28, 2006 at 23:23
ThreadID: 40691 Views:5174 Replies:16 FollowUps:12
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Well I have got it mounted! I posted some time back asking about whether it could be done without a winch bar and thanks to some responses I have made it happen. ( For an accountant I am pretty chuffed with the results.....had some help from some talented family I must admit and I thank them). Thanks to all who gave advice, I particularly had the courage to proceed due to Robins posting of is similar experience.

In my Rig Gallery I have posted 7 pics of the build up for anyone who is interested.
The install was done without altering any of the existing structure.

Unlike Robin's install, my radiator and fan set-up did not allow mounting on a flat bar and I was forced to drop everything about 5cm. I also didn't have any points below to mount off of.

I decided to go heavier steel to compensate. It is all 150mm wide. The bottom plate is 10mm thick (I wanted to use 8mm but the steel merchant didn't have any and gave me 10mm for the same price.....what's a bit of extra weight?).

I couldn't run flush down the side of the chassis rails because the bumper mountings protrude. Angle iron is stonger than welding and I wanted to bolt the base rather than weld to give a bit of allowance for flex etc.

In the end got 4 pieces of 6mm x 150 long angle and welded them into two "Z's". The 10mm plate sits between them and there is an upright 6mm plate welded to the front with a cutout for the fairlead.

All pretty easy in the end (lots of trial and error in the middle....including a few welds that had to be broken) but I think it has worked out ok. The hardest bit has been to relocate the number plate!

Still have to mount the electronics side of it all in the engine bay (need some longer cables etc) (plus find somewhere to mount it).

Hope this helps anyone else contemplating it.

Happy new year
Trev
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Reply By: Member - John - Thursday, Dec 28, 2006 at 23:33

Thursday, Dec 28, 2006 at 23:33
Trev, not sure what you have done with the number plate, if anything? How about fitting a couple of tool clips to the plate and then clipping these to the rollers on the fair lead? Remove number plate when required. Just a thought. John
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Follow Up By: Trevor M (SA) - Thursday, Dec 28, 2006 at 23:36

Thursday, Dec 28, 2006 at 23:36
Hi John,

Not sure what you mean by "tool clips but interested in any ideas.

As I said in the post re-locating the number plate was a pain, and I haven't got it right yet. I have fabricated a couple of brackets off the bar to the drivers side but "it looks like an accountant made it!" LOL

Cheers
Trev
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Reply By: MickO13 - Thursday, Dec 28, 2006 at 23:34

Thursday, Dec 28, 2006 at 23:34
Mate you are one in touch accountant. Cheers. Mick.
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Follow Up By: Trevor M (SA) - Friday, Dec 29, 2006 at 00:09

Friday, Dec 29, 2006 at 00:09
Thanks Mick,

Had some talented help (I passed the tools etc)....but I must say I did all the measuring....which is everything right?

Trev (measuring is just numbers and accountants are good with numbers)

(Thanks to my mates who did the welding etc)
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Reply By: Member - John - Thursday, Dec 28, 2006 at 23:39

Thursday, Dec 28, 2006 at 23:39
Trevor, after looking at your pics, I think I would have added some gussets at each end of the fairlead plate, I think you may have a problem when winching, of the plate folding forward under load. The gussests will help to prevent this. Just my two bobs worth. John
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Follow Up By: Trevor M (SA) - Thursday, Dec 28, 2006 at 23:46

Thursday, Dec 28, 2006 at 23:46
Hi John,

I must admit I was more worried about the stresses on the mount itself than the fairlead plate but it is 6mm and trust me it is "jammed in there" so tight ( as is everything LOL) I dont think it will budge. It's all so tight in there that if something gives the whole front end will come off! ( and I must admit to giving that some concern!)

Trev
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Reply By: Member - John - Thursday, Dec 28, 2006 at 23:43

Thursday, Dec 28, 2006 at 23:43
Trevor, not sure why we are both up at this time of night, LOL, but tool clips are thingies that hold all sorts of tools, clip around round things etc. Available up to 32 mm, but pretty sure fairleads are only 25mm.

http://www.springmasters.com/sp/images/open-spring-clip.jpg

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Reply By: Member - John - Thursday, Dec 28, 2006 at 23:50

Thursday, Dec 28, 2006 at 23:50
Trevor, the only thing holding the winch in place is the front plate, it may be 6mm, but the only thing holding the plate in place is the weld at the bottom, a small gusset weldied in each end would help no end to stop the plate twisting downwards when under load. John
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Follow Up By: Trevor M (SA) - Thursday, Dec 28, 2006 at 23:54

Thursday, Dec 28, 2006 at 23:54
Hi John,

The winch is bolted by 4 bolts down into the 10mm plate at the bottom.

Trev
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Follow Up By: Trevor M (SA) - Thursday, Dec 28, 2006 at 23:58

Thursday, Dec 28, 2006 at 23:58
Showing my ignorance I know, but can you please elaborate on what you mean by a "gusset weld"?

Sorry,
Trev
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Reply By: Member - John - Friday, Dec 29, 2006 at 00:02

Friday, Dec 29, 2006 at 00:02
Trevor, shows my ignorance, most winches are bolted thru the fairlead, didn't realise that your was bolted thru the bottom plate. Shouldn't move. "gusset weld" is a plate welded at 90o at each end of the front plate to provide a support to the front plate. Hope that makes sense? John
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Follow Up By: Trevor M (SA) - Friday, Dec 29, 2006 at 00:05

Friday, Dec 29, 2006 at 00:05
Cheers John,

Time we were both in bed! Thanks for your comments, I hope it all holds up when the time comes to test it!

Trev
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Follow Up By: Exploder - Friday, Dec 29, 2006 at 00:16

Friday, Dec 29, 2006 at 00:16
150mm* 10mm steal plate, yeah don’t see that buckling under load, Those rear bolts would fail before that plate started to twist.
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Follow Up By: Trevor M (SA) - Friday, Dec 29, 2006 at 00:19

Friday, Dec 29, 2006 at 00:19
That's my thoughts / hope!
Trev
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Reply By: Member - John - Friday, Dec 29, 2006 at 00:09

Friday, Dec 29, 2006 at 00:09
Ditto to both. John
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Reply By: Trevor M (SA) - Friday, Dec 29, 2006 at 00:24

Friday, Dec 29, 2006 at 00:24
sorry for anyone taking down dimensions, the angle iron I used is 75 x 75 (by 6mm)
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Reply By: geocacher (djcache) - Friday, Dec 29, 2006 at 04:22

Friday, Dec 29, 2006 at 04:22
Hi Trevor.

Looks good, be interesting to hear how it works. I'm not sure why you didn't change to a proper bar, I must have missed an earlier thread.

Were any calcs done to determine method and materials used?

Also have you given any thought to where you'll attach to for a double line pull?

Dave
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Follow Up By: Trevor M (SA) - Friday, Dec 29, 2006 at 09:07

Friday, Dec 29, 2006 at 09:07
Hi Dave,

In terms of not changing to a winch bar it was really that it seemed an unnecessary cost. I didn't do any strict calcs etc on stresses but recommended was 6mm so went heavier. All bolts are high tensile etc.

In terms of double line pull the original recovery point is still there . It can just be seen in the background on the 4th photo.

Trev
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Follow Up By: geocacher (djcache) - Saturday, Dec 30, 2006 at 08:34

Saturday, Dec 30, 2006 at 08:34
Well it looks great, the reasoning is sound. Time will tell.

I'd give it a bit of a flogging in the presence of others to get you out if something fails but all being well I don't reckon it will.

I can see a market for it if it all goes well, but the engineering and probably crash testing requirements would probably make it cost prohibitive for something you'd only be able to charge a couple of hundred $$$ for.

I reckon it's a bit like my fridge hinge. Put it out there for the masses to help themselves to. And sit back and feel really good when people like the idea enough to copy for themselves.

Maybe we'll see a commercial manufacturer take the idea on and you can get an idea in the top ten 4wd products for 2007.... I cracked 2005.

Watching with great interest.

Dave
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Reply By: Mike Harding - Friday, Dec 29, 2006 at 09:56

Friday, Dec 29, 2006 at 09:56
Nice one Trevor.

Just goes to show we don't need to follow the flock which is often prevalent on this site, you know; "Better use the proper [they mean commercial] stuff if you value your family's safety mate".

Looks like a strong and neat job, well done.

Mike Harding
AnswerID: 212389

Reply By: turbopete - Friday, Dec 29, 2006 at 11:26

Friday, Dec 29, 2006 at 11:26
why not use a winch bar????
AnswerID: 212398

Reply By: Trevor R (QLD) - Friday, Dec 29, 2006 at 14:28

Friday, Dec 29, 2006 at 14:28
Hi Trevor,

I can see why you are pretty chuffed with the job. I hope you have measurements of everything cause if it works well, why don't you sell either the idea or the bits required for DIY interested GU owners. I see a market for it. Looks to me like the winch was always meant to be there.

Happy new year
Trevor R.
AnswerID: 212410

Reply By: Member - Duncan W (WA) - Friday, Dec 29, 2006 at 19:46

Friday, Dec 29, 2006 at 19:46
Trevor, that looks excellent. One question though how does it go with air bag compliance or don't GU's have air bags? Not being sarcastic with the question genuinely interested as a winch for a Terracan (my vehicle) is not available and your set-up would be a good option.
Dunc
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Follow Up By: Trevor M (SA) - Friday, Dec 29, 2006 at 23:30

Friday, Dec 29, 2006 at 23:30
Short answer Duncs is that I don't know. The GU certainly has airbags but nothing I did would appear to have any bearing on anything that might be connected with them??

Fingers crossed...
Trev

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Follow Up By: acdc - Saturday, Dec 30, 2006 at 23:10

Saturday, Dec 30, 2006 at 23:10
Trevor M
Looks good!
Strictly speaking its not airbag compatible, but don't tell anyone!
A TJM winch frame would of done the job and airbag compatible.
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Reply By: Member - John (Vic) - Saturday, Dec 30, 2006 at 23:22

Saturday, Dec 30, 2006 at 23:22
Good Job Trevor, looks like it was meant to be there.

Would be interested in hearing how it goes under load sometime in the future and maybe a few pics posted on here.

Cheers
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Reply By: Luke SA - Sunday, Dec 31, 2006 at 00:48

Sunday, Dec 31, 2006 at 00:48
As said above Trevor a very good job, looks like it was meant to be there and a very simple design. I hope it does the job for you in the future and doesnt fail on you

Cheers Luke
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Reply By: navaraman - Sunday, Dec 31, 2006 at 18:49

Sunday, Dec 31, 2006 at 18:49
That looks real good Trev.

Patrolman Pat
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