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- Oct 13, 2010
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Toyota Dyna Winch Bumper
I had another busy week at work, only a short one as Monday was a public holiday as it was the Queens birthday.
I've been busy working on my bosses latest toy, his tip truck.
I needed to replace the rotten front cross member and build a new front bumper with a big 12,000LB winch mounted in it.
The rotten cross member was riveted in position so I had to grind the heads off the rivets and punch them out.
I ended up having to slice it down the middle to get it off.
Cut some 90mm x 10mm flat to length and ground the corners off 2 edges to fit snugly in the chassis rails, this would give me something nice and strong to mount the winch off.
Drilled some holes in it to line up with existing holes in the chassis.
Bolted in position.
Cut and drilled some 75mm x 50mm angle to replace the rotten chassis cross member.
Cut and drilled another for the bottom.
Used the oxyacetylene torch to notch out the 90mm flat to allow the winch to sit lower.
With no machine big enough to cut the 200mm x 6mm flat I needed to use for the winch to bolt to, I clamped a straight edge to it and cut it with the 9" grinder.
Drilled it for the winch and ground the mill scale off where I intended on welding.
Prepared the 90mm flat for welding by beveling the edges to ensure good weld root penetration.
Used the trolley jack to lift the piece of 200mm flat up into position and bolted it to the bottom of the winch and tack welded the 200mm to the 90mm.
Front section next, again out of the 200mm x 6mm.
Marked and drilled.
Joined the holes up with the grinder.
The fairlead bolts through the 6mm into the winch. This would mean the winch will be bolted in position with 4 bolts coming up from the base and 2 through the front so should be nice and strong.
Bolted it on and tack welded the 200mm front to the rest of the winch mount.
The winch had to be mounted quite far forward to clear the tilting cab.
Cardboard template next for the wings.
Ended up taking a bit more off the template and then cut some 3mm sheet steel and tacked it on.
Next template.
Cut and tacked in position.
Other side.
End sections.
Decided to add a solid back section, not something you would normally have on a winch bumper, but then this isnt a normal winch bumper with it being mounted so far forward from the cab and me wanting it to be very strong.
Fully welded around the top.
I wanted to add some tube next. 2" would have been far too small so I opted for 3".
Sadly we cant bend 3" in our bender so I only had one option which was to cut and shut some narrow hoops we already had left over from Vitara winch bumpers.
Used some big angle to help keep it all alined while I TIG welded it.
Went for a 1.6mm gap as having them fitted tight would have effectively meant when I ground the weld down afterwards I would have ground all the reinforcement away and it would have been pretty weak.
Ground the welds down.
Cut 10mm to nothing off the bottom of both sides of the hoop to lean it forward slightly away from the tilting cab.
Decided to add a light-bar next so I grabbed one out of the show room.
Welded some brackets onto the hoop for the light-bar, ground the welds down along the top of the winch bumper and then welded the hoop on.
Removed the bumper.
Removed the winch and light-bar and made a start fully welding it all.
Decided to add a reciever hitch so that a front recovery point can be slid in for either snatch recoveries and/or an anchor point for the winch when using a snatch block. It will also be useful for moving big trailers around with a towball slid in.
Put 2 cuts in with the angle grinder then joined them up with the oxy torch.
Cleaned it up with the finger linisher.
I wasnt able to use a conventional receiver hitch pin as it will be tricky to get to the other side to get the R clip in and out. So I picked up an M16 bolt instead and I will weld a wing-nut style wing to the bolt head.
Welded the nut on to create a captive nut.
Still need to weld it in position but it will sit like this.
In preparation for the re-spray we got the sides of the pick up bed shotblast.
And thats as far as I got!
I need to finish the bumper and get it powdercoated and re-fitted. We've ordered 6 mud tyres to hopefully stop the 2wd (well technically its a 4wd, as theres 4 tyres on the driven rear axle) Dyna from getting stuck in the fields (padocks as there called here).
The new tyres will be mounted on the original wheels which we will get shotblast and powdercoated.
Then theres the re-spray/paint work to do.
The drivers seat has just come from back from being repaired and re-upholstered and looks great.
The engine has also had a bit of work done on the cooling system which was all pretty rotten.
So a bit more work and then it can go off and have some fun with the excavator! It will come in very handy when my boss starts building the mote around his farm house!
We need to get back on the airboat project and get the propeller ordered from the states.
The huge gum tree should have been cut down by now ready for me to build the big 3 storey tree house for it, which will be built in pre-fabricated sections at work and then taken to the farm, lifted up into the tree and bolted together.
I've also got a tiny bit more work to do on the solar car for next months Simpson Desert crossing.
In the mean time I've picked up more supplies and my entire weekend will be spent practicing welding pieces of pipe, Again!
This is what I've been getting through every week!
A $50 bottle of argon.
And a crate full of machined pipe and filler rod.
The big test is 2 weeks tomorrow so I'm practicing like crazy!
Hoping the Sunday after the test I can finally get back on with LJ!
I had another busy week at work, only a short one as Monday was a public holiday as it was the Queens birthday.
I've been busy working on my bosses latest toy, his tip truck.
I needed to replace the rotten front cross member and build a new front bumper with a big 12,000LB winch mounted in it.
The rotten cross member was riveted in position so I had to grind the heads off the rivets and punch them out.
I ended up having to slice it down the middle to get it off.
Cut some 90mm x 10mm flat to length and ground the corners off 2 edges to fit snugly in the chassis rails, this would give me something nice and strong to mount the winch off.
Drilled some holes in it to line up with existing holes in the chassis.
Bolted in position.
Cut and drilled some 75mm x 50mm angle to replace the rotten chassis cross member.
Cut and drilled another for the bottom.
Used the oxyacetylene torch to notch out the 90mm flat to allow the winch to sit lower.
With no machine big enough to cut the 200mm x 6mm flat I needed to use for the winch to bolt to, I clamped a straight edge to it and cut it with the 9" grinder.
Drilled it for the winch and ground the mill scale off where I intended on welding.
Prepared the 90mm flat for welding by beveling the edges to ensure good weld root penetration.
Used the trolley jack to lift the piece of 200mm flat up into position and bolted it to the bottom of the winch and tack welded the 200mm to the 90mm.
Front section next, again out of the 200mm x 6mm.
Marked and drilled.
Joined the holes up with the grinder.
The fairlead bolts through the 6mm into the winch. This would mean the winch will be bolted in position with 4 bolts coming up from the base and 2 through the front so should be nice and strong.
Bolted it on and tack welded the 200mm front to the rest of the winch mount.
The winch had to be mounted quite far forward to clear the tilting cab.
Cardboard template next for the wings.
Ended up taking a bit more off the template and then cut some 3mm sheet steel and tacked it on.
Next template.
Cut and tacked in position.
Other side.
End sections.
Decided to add a solid back section, not something you would normally have on a winch bumper, but then this isnt a normal winch bumper with it being mounted so far forward from the cab and me wanting it to be very strong.
Fully welded around the top.
I wanted to add some tube next. 2" would have been far too small so I opted for 3".
Sadly we cant bend 3" in our bender so I only had one option which was to cut and shut some narrow hoops we already had left over from Vitara winch bumpers.
Used some big angle to help keep it all alined while I TIG welded it.
Went for a 1.6mm gap as having them fitted tight would have effectively meant when I ground the weld down afterwards I would have ground all the reinforcement away and it would have been pretty weak.
Ground the welds down.
Cut 10mm to nothing off the bottom of both sides of the hoop to lean it forward slightly away from the tilting cab.
Decided to add a light-bar next so I grabbed one out of the show room.
Welded some brackets onto the hoop for the light-bar, ground the welds down along the top of the winch bumper and then welded the hoop on.
Removed the bumper.
Removed the winch and light-bar and made a start fully welding it all.
Decided to add a reciever hitch so that a front recovery point can be slid in for either snatch recoveries and/or an anchor point for the winch when using a snatch block. It will also be useful for moving big trailers around with a towball slid in.
Put 2 cuts in with the angle grinder then joined them up with the oxy torch.
Cleaned it up with the finger linisher.
I wasnt able to use a conventional receiver hitch pin as it will be tricky to get to the other side to get the R clip in and out. So I picked up an M16 bolt instead and I will weld a wing-nut style wing to the bolt head.
Welded the nut on to create a captive nut.
Still need to weld it in position but it will sit like this.
In preparation for the re-spray we got the sides of the pick up bed shotblast.
And thats as far as I got!
I need to finish the bumper and get it powdercoated and re-fitted. We've ordered 6 mud tyres to hopefully stop the 2wd (well technically its a 4wd, as theres 4 tyres on the driven rear axle) Dyna from getting stuck in the fields (padocks as there called here).
The new tyres will be mounted on the original wheels which we will get shotblast and powdercoated.
Then theres the re-spray/paint work to do.
The drivers seat has just come from back from being repaired and re-upholstered and looks great.
The engine has also had a bit of work done on the cooling system which was all pretty rotten.
So a bit more work and then it can go off and have some fun with the excavator! It will come in very handy when my boss starts building the mote around his farm house!
We need to get back on the airboat project and get the propeller ordered from the states.
The huge gum tree should have been cut down by now ready for me to build the big 3 storey tree house for it, which will be built in pre-fabricated sections at work and then taken to the farm, lifted up into the tree and bolted together.
I've also got a tiny bit more work to do on the solar car for next months Simpson Desert crossing.
In the mean time I've picked up more supplies and my entire weekend will be spent practicing welding pieces of pipe, Again!
This is what I've been getting through every week!
A $50 bottle of argon.
And a crate full of machined pipe and filler rod.
The big test is 2 weeks tomorrow so I'm practicing like crazy!
Hoping the Sunday after the test I can finally get back on with LJ!
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