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DMAC's Winch Bar Build MKII for LWB.
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Author:  DMAC [ Sun Apr 26, 2009 11:04 pm ]
Post subject:  DMAC's Winch Bar Build MKII for LWB.
Well at last I've got a few things together to start my build. :woohoo:
I'm starting with a 12000lb tigerzz winch with synthetic rope. I got a mate to make the housing for the winch. Thought a professional to do this bit as I don't want any thing to go pear shaped in the middle of a recovery. I did the design so here we go.

First I fabbed up a solenoid bracket to remote mount solenoid as I didn't like the look of the control box on top of the winch.
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Mounted this beside the radiator.
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Installed the remote manual selector switch in the cab. May also wire in in cab in/out operation. Possibly not needed as you can use the remote.
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The bracket to go onto the front chasis bar. I've got 4 to put on but I think that'll be overkill. Might only use 2.
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Winch Housing.
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Winch installed. A little filing required to get the front bolts in.
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Mounted on the front.
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Side view. Doesn't protrude to far in frontof the original bar profile. No change to approach angle.
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Fairlead goes here.
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Everthing was only roughly fitted just to make sure I didn't have to make any alterations to it.
Things to do.
Get some 32nb bar to do the wings of the bar.
Get myself a MIG.(Hurry up K Rudd I need to spend)
Fab the side bars.
Fit a larger capacity battery.
Paint the bar.
Refit and finish wiring.

Go wheelin get stuck and pull myself out. :wink:

For those interested I measured the height of the front to see how much sag the extra weight would add. Dropped it 5m on the drivers side and 10m on th passngers side. I'll have to wait and see wait affect it will have on the ride.

Will post up more as I progress.
Author:  meads02 [ Tue Apr 28, 2009 9:25 pm ]
Post subject:  Re: DMAC's Winch Bar Build
Lookin good DMAC. Are you planning on getting really stuck? :D

What other mods have you got planned? Gears and a locker??
Author:  Saam [ Tue Apr 28, 2009 10:57 pm ]
Post subject:  Re: DMAC's Winch Bar Build
Dropped 10 Metres on the passengers side !!!

that could be a real issue !

lol
Author:  Pubic [ Wed Apr 29, 2009 1:38 pm ]
Post subject:  Re: DMAC's Winch Bar Build
^ was just thinking that! even 5 metres on drivers side.... wow! it must be a 12tonne winch.

looks good though mate, will there be any drainage holes to be rid of water after washing it out?
Author:  DMAC [ Thu Apr 30, 2009 11:22 am ]
Post subject:  Re: DMAC's Winch Bar Build
:oops: The droop goes with 20m travel of the zook. :oops:
The young fella pointed out the need for some drain holes. I think he snoops around this forum too much.
Picked up the tube for the sides yesterday.
Hopefully a weekend of blokey stuff coming up. :D
Author:  Lokidog [ Sat May 02, 2009 3:45 pm ]
Post subject:  Re: DMAC's Winch Bar Build
Where are you putting your front number plate? To the side of the winch?

Where's Grimbo?? There could be legal issues here!
Author:  DMAC [ Sat May 16, 2009 1:56 am ]
Post subject:  Re: DMAC's Winch Bar Build
:evil: Let me share a few things I have learnt about pipe benders.
They suck.
I had access to a $12K electonically controlled job, a manual draw bender with straight outer former, and a hydraulic ram bender.
Don't bother using a bender unless it has the correct sized dies. :oops:
Light gauge 32nb ain't the easiest pipe to bend.

Ended up using the ram bender with water pipe. Not as light but it bends.

Hopefully will make some progress this weekend. :?
Author:  hooki [ Sun May 17, 2009 2:55 am ]
Post subject:  Re: DMAC's Winch Bar Build
looks awesome so far.
Author:  DMAC [ Sun May 17, 2009 10:33 pm ]
Post subject:  Re: DMAC's Winch Bar Build
Welded the extra brackets on

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Tacked on the side bars.

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Lots of welding grinding and cutting to go but I'm making progress.
Not sure whether to paint it myself or get it powder coated?

Considering numberplate mounting. Thinking of mounting on a hinge arrangement and fold it out of the way when using the winch.
Author:  dano_mung [ Wed May 20, 2009 1:26 am ]
Post subject:  Re: DMAC's Winch Bar Build
Powder coat for sure!
It's not that expensive really in the long run as you'll never have to do it again hopefully, and you should be able to pick a coating to suit your application (heat, impact, surface).

Great work on the whole thing mate.
Your mate who built it did an excellent job.

And I agree there does need to be some drain holes under the winch to let water out, and I would also think about airflow to the winch and engine as they run bloody hot.
Author:  DMAC [ Mon Jun 01, 2009 10:11 pm ]
Post subject:  Re: DMAC's Winch Bar Build
Done and dusted. Finished the install Friday night. Pretty happy how it turned out. Number plate still a little bit of an issue but happy to remove it when needed.

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All I have to do now is upgrade the battery. :)

Sliders are next.
Author:  Mike [ Mon Jun 01, 2009 11:12 pm ]
Post subject:  Re: DMAC's Winch Bar Build
looks awesome mate
you might think of getting some smaller indicators and part lights that can sit further back in the bar so you don't smash them on trees and shit
Author:  Saam [ Tue Jun 02, 2009 4:53 pm ]
Post subject:  Re: DMAC's Winch Bar Build
i doubt you'd break them, the suzuki ones look good, mount the number plate on the angled piece below the winch ripe guide thing, won't be any more illegal than that rest of it
Author:  DMAC [ Sat Apr 28, 2012 4:15 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
OK starting to build a winch bar for the LWB. I wanted to get the winch back as far as I could to take advantage of the 2" body lift. It will sit about 75mm further back than the SWB.
It will also be a normal type bar. Ie. Not a tube bar.
I am trying to bring together a lot of what I consider the best bits of the bar builds here.

Mounting style has to be Balls uber strong mounts.

Pics.

Plate notched and positioned. 6mm plate being used.
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Mounting winch plate to the inside.
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All positioned and ready to glue together.
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Author:  rob_macca67 [ Sat Apr 28, 2012 6:15 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
Looking good there Dave.... will it be ready by Wed ??? :)
Author:  DMAC [ Sat Apr 28, 2012 6:24 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
rob_macca67 wrote:
Looking good there Dave.... will it be ready by Wed ??? :)


:deadhorse: Nup.

Lockies goes though. :wink:
Author:  matty_wall [ Sat Apr 28, 2012 6:37 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
Subscribed!
Bar looks the goods
Ill be stealing your ideas :)

Matt
Author:  hooki [ Mon Apr 30, 2012 1:11 am ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
thats looking like it's going to be a strong bar :) good work so far
Author:  DMAC [ Mon Apr 30, 2012 8:04 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
Got Lockie to do a bit more welding tonight and should finish the mounting plates on the chasis tomorrow.
Bought all the mounting bolts too.

Still haven't quite firmed up the actual bar design. I will have to mount the front flares to get all the lines to flow.

More pics soon.
Author:  ZookFan [ Mon Apr 30, 2012 8:12 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
Looks great mate!
Author:  Bruce [ Mon Apr 30, 2012 8:16 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
rob_macca67 wrote:
Looking good there Dave.... will it be ready by Wed ??? :)

Another secret run hey :roll:
Author:  DMAC [ Mon May 07, 2012 5:16 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
Done. pompoms

I take my hat off to Joeblow and Fatzook there is so much work in designing and manufatcture of a bar.
I spent about $150 on materials, another $80 at least in consumables, Gas, welding wire, cutoff discs, ect.....
Another 2 full days of cutting welding grinding all for a mediocure result. :?
Any front bar under $1000 bucks is well worth it.

Trying to bend plate without proper panbrake or 90 degree blocks and press to get a good result is not possible. :oops:

Anyway I have finally finished it,sits a little lower than I would have liked.

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It will eventually have some 3" fog lights at the side. I have left some gaps as highlift jacking points.

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The bar sits wide to cater for when I get around to installing these. :wink:

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Author:  Rusho [ Mon May 07, 2012 5:24 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
Looks pretty good mate. Well done yet again boys pompoms pompoms :mrgreen:
Author:  fully sick coily [ Sun May 13, 2012 11:13 am ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
very nice 5 stars
Author:  DMAC [ Sun May 13, 2012 8:35 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
Mounted spotties and wired in cab winch controls yesterday.

Spotties make it look much better. Got its first scatch today. :)
Author:  ZookFan [ Mon May 14, 2012 5:39 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
I personally think it looks great! 8)
Author:  fully sick coily [ Mon May 14, 2012 6:01 pm ]
Post subject:  Re: DMAC's Winch Bar Build MKII for LWB.
pic?



:mrgreen:
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