Trevor
Well-Known Member
- Joined
- Jul 25, 2010
- Messages
- 1,889
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I've wanted a behind bumper winch in the 120 for a while now, so this week I trundled up to North Lincs and spent a couple of days with ChrisGreen90 in his workshop where he was going to fabricate something from scratch.
I was greeted with a nice sight to start the day off right and keep the unit toasty.
Off with the bumper and front crossmember.
A bit of work in wood to template up bits and pieces.
" I said, do you do Liver?"
The aircon pipe needed to be moved back nearer to aircon rad, the metal bracket was removed and the clip reused to hold it in place.
A man's band saw
Cue the A Team music.
I had a standard tray which was cut and modified to fit.
New brackets made to fit the existing bolts on the end of the chassis rail and ready for tacking to the tray.
I had the job of cutting my own bumper to set the fairlead positioning.
I forgot to take photos at various stages, largely due to a mixture of excitement from playing with a flappy wheel grinder, MIG welder (Chris corrected my 3" run
) and making the odd brew but eventually this is what we had, including the swivel eye recovery points.
Chris drilling the recovery points.
This seems to be a common pose while Chris works, maybe it's Hull thing
So then I got to paint it.
Then we got to fitting it on the truck.
There were 2 holes that were perfectly positioned to mount the relay, just needed threading.
The Champion winch I was originally going to use packed in, so I convinced Mrs Trev to match the Dyneema I'd already bought with a TDS 9.5 Goldfish
I was going to install the Dyneema through the drum and use the grub screws, I was shown a different way which I thought I would see if it's as good as claimed. Essentially it's a couple of turns on the drum, loop over the incoming rope and splice back in to make a kind of noose, this slides down to the drum and you wind it on. I'm sure there will be some views on this method so let the discussion begin.
Refit the bumper. Now you see me....
.... now you don't.
We ran out of time to fettle in a kill switch, hinge/trim the number plate and mount the wander lead socket but these I can do later. Chris also made up the brackets to fasten the underside of the bumper back to the factory bash plate.
I can't thank Chris enough, not only was it a good couple of days of banter but I was really impressed with the attention to detail, workmanship, problem solving and skill set that Chris has. I'm truly delighted in a bespoke and rugged solution for my truck. Squeezing in this winch into the space available with only a few millimeters to play with takes some doing, top job Chris
.
After driving home and allowing the suspension to settle, the front is now 15mm lower.............springs next year perhaps with suspension to go with it?
I was greeted with a nice sight to start the day off right and keep the unit toasty.
Off with the bumper and front crossmember.
A bit of work in wood to template up bits and pieces.
" I said, do you do Liver?"
The aircon pipe needed to be moved back nearer to aircon rad, the metal bracket was removed and the clip reused to hold it in place.
A man's band saw
Cue the A Team music.
I had a standard tray which was cut and modified to fit.
New brackets made to fit the existing bolts on the end of the chassis rail and ready for tacking to the tray.
I had the job of cutting my own bumper to set the fairlead positioning.
I forgot to take photos at various stages, largely due to a mixture of excitement from playing with a flappy wheel grinder, MIG welder (Chris corrected my 3" run
) and making the odd brew but eventually this is what we had, including the swivel eye recovery points.Chris drilling the recovery points.
This seems to be a common pose while Chris works, maybe it's Hull thing
So then I got to paint it.
Then we got to fitting it on the truck.
There were 2 holes that were perfectly positioned to mount the relay, just needed threading.
The Champion winch I was originally going to use packed in, so I convinced Mrs Trev to match the Dyneema I'd already bought with a TDS 9.5 Goldfish
I was going to install the Dyneema through the drum and use the grub screws, I was shown a different way which I thought I would see if it's as good as claimed. Essentially it's a couple of turns on the drum, loop over the incoming rope and splice back in to make a kind of noose, this slides down to the drum and you wind it on. I'm sure there will be some views on this method so let the discussion begin.
Refit the bumper. Now you see me....
.... now you don't.
We ran out of time to fettle in a kill switch, hinge/trim the number plate and mount the wander lead socket but these I can do later. Chris also made up the brackets to fasten the underside of the bumper back to the factory bash plate.
I can't thank Chris enough, not only was it a good couple of days of banter but I was really impressed with the attention to detail, workmanship, problem solving and skill set that Chris has. I'm truly delighted in a bespoke and rugged solution for my truck. Squeezing in this winch into the space available with only a few millimeters to play with takes some doing, top job Chris
.After driving home and allowing the suspension to settle, the front is now 15mm lower.............springs next year perhaps with suspension to go with it?
(Unless I have missed something 
)
The sky's the limit mate!
