Author Topic: Warn Powerplant on Marlin bumper build (Read 7583 times)

germ · « **on:** Sep 19, 2009, 01:39:42 PM »

I needed to somehow fit my new Warn Powerplant on the front of my 4Runner. I thank those who went before, and gave me some ideas. I finally decided on Marlin's bumper without the stinger. Damned winch weighs 100lbs, and I didn't want to have to lift it over the stinger. So, here is what I had to do to get it to fit.

Erik

germ · « **Reply #1 on:** Sep 19, 2009, 01:44:35 PM »

So, the motor side of the winch sits a bit lower and wider than the support. I considered making a new one all together, but that seemed like too much work. I decided to cut into the existing support and box it to maintain strength.

germ · « **Reply #2 on:** Sep 19, 2009, 01:48:21 PM »

Also, the support put on by Marlin stuck up just a bit too much, so I had to grind it down some.

germ · « **Reply #3 on:** Sep 19, 2009, 01:50:53 PM »

I wanted to keep the cutting to a minimum, and you can see how tight a fit it is.

germ · « **Reply #4 on:** Sep 19, 2009, 01:52:35 PM »

From a different angle you can see it's still pretty tight in there.

germ · « **Reply #5 on:** Sep 19, 2009, 02:03:45 PM »

Now it sits level. Before the passenger side was up about 1/2 inch.

germ · « **Reply #6 on:** Sep 19, 2009, 02:05:54 PM »

Side view

germ · « **Reply #7 on:** Sep 19, 2009, 02:07:35 PM »

Then I finished boxing the cut, grinding it all down nicely, then it was off to the wood pile for paint.

germ · « **Reply #8 on:** Sep 19, 2009, 02:10:51 PM »

I also welded on some tabs to mount some small Wally-world special $15 dolloar driving lights. Here is the finished product.

germ · « **Reply #9 on:** Sep 19, 2009, 02:12:24 PM »

From a different perspective. As you can see, I still had some wiring to do.

germ · « **Reply #10 on:** Sep 19, 2009, 02:16:09 PM »

Don't have a picture of it, but I used an old-style steel hawse fairlead to protect the wire. The roller fairlead that came with the winch won't fit because of the upper tube. Thought about fabbing up a piece to move it forward some, but ran out of time before MCR8, and figured it would work this way just fine. Besides, eventually I plan to switch to synthetic line, and I'll go back to the hawse type fairlead anyway.

blackdiamond · « **Reply #11 on:** Sep 19, 2009, 06:41:14 PM »

Quote from: germ on Sep 19, 2009, 01:44:35 PM

I decided to cut into the existing support and box it to maintain strength.

Hopefully you don't have any problems with this mod, you reduced its ability to resist bending up and down by a significant amount. The cross section is greatly reduced in the vertical direction.

I'd consider replacing that support with another one as close to the winch as possible.

87pickup · « **Reply #12 on:** Sep 19, 2009, 07:18:07 PM »

On my dads we plated from tube to tube under the winch motor and opposite side to help stiffen everything back up. They are a big winch for sure. $Beer Chug\'n$

germ · « **Reply #13 on:** Sep 20, 2009, 12:12:24 PM »

Yea, I've thought about that, and have thought about 1/2 sleeving the remaining tube to make it stronger. i've also considered additional bracing, but haven't decided on anything as of yet.

I'd be interested in seeing a picture of the plating you did 87PU.

Erik

axled89 · « **Reply #14 on:** Sep 22, 2009, 03:05:37 PM »

damn that thing is huge. looks like bubba gumps bottom lip.

junya92toy · « **Reply #15 on:** Sep 22, 2009, 06:46:55 PM »

Should of got a winch plate and welded in there.

http://www.budbuilt.com/new/winch_plates.html

axled89 · « **Reply #16 on:** Sep 22, 2009, 07:38:40 PM »

looks like your gonna need a roll bar for the winch. just in case. looks like it sit's pretty tall. just my

germ · « **Reply #17 on:** Sep 26, 2009, 04:30:18 PM »

Quote from: jerry92toy on Sep 22, 2009, 06:46:55 PM

Should of got a winch plate and welded in there.

http://www.budbuilt.com/new/winch_plates.html

I looked at that option, and there were a few others out there as well. The problem was that I really didn't want to do that much fabrication before heading out to MCR8. Fortunately, where the cut is doesn't affect the stability of the winch mount, only the resistance to bending in a front impact. I don't plan on getting into a front impact accident (who does?), but I still want to bolster that area some.

Erik

germ · « **Reply #18 on:** Sep 26, 2009, 04:33:18 PM »

Quote from: axled89 on Sep 22, 2009, 07:38:40 PM

looks like your gonna need a roll bar for the winch. just in case. looks like it sit's pretty tall. just my

Yea, I agree, it's a monster. I was worried about it affecting air flow thru the radiator, and subsequent overheating issues. It didn't affect a thing. The temp guage sat right where it always does, and didn't budge. I was happy with that. The addition of the air compressor really make the thing huge, but it is really nice to have on the trail. Other nice thing is that it doesn't take up a bunch of room in the back of the truck.

I plan on making a front hoop to protect it some, and make some hoops to go around the front fenders as well. I didn't really like how the stinger on marlins bumper looked, so I figured I'd make my own.

Erik

axled89 · « **Reply #19 on:** Sep 30, 2009, 08:37:07 PM »

hey man! i'm just teasing yu. my 9.5 ti. is a monster to.

germ · « **Reply #20 on:** Nov 02, 2009, 09:24:30 PM »

Yea, no worries. I know what you mean. Those things seem to be getting bigger and bigger.

Volcom · « **Reply #21 on:** Nov 03, 2009, 07:45:49 AM »

Quote from: jerry92toy on Sep 22, 2009, 06:46:55 PM

Should of got a winch plate and welded in there.

http://www.budbuilt.com/new/winch_plates.html

Cheaper winch plate, same winch plate that Marlin uses on their bumpers.
http://www.datinfab.com/winchplate.aspx

I bought one a while back, nice quality product!

Dropmytaco · « **Reply #22 on:** Nov 03, 2009, 10:00:14 AM »

i love this winch and have sold several. the convience of the air just makes it a bad ass tool.

but its soo tall !

jonathan82toy · « **Reply #23 on:** Nov 03, 2009, 10:25:17 AM »

Quote from: Volcom on Nov 03, 2009, 07:45:49 AM

Cheaper winch plate, same winch plate that Marlin uses on their bumpers.
http://www.datinfab.com/winchplate.aspx

I bought one a while back, nice quality product!

UMMm, Its not that same plate we use.

Where did you hear that?

ajordan1975 · « **Reply #24 on:** Nov 03, 2009, 10:34:15 AM »

What about air flow through the radiator?

Looks like it blocks the whole thing....

Nevermind...... I actually read the whole thing after I posted this.

Volcom · « **Reply #25 on:** Nov 03, 2009, 02:45:18 PM »

Quote from: jon82toy on Nov 03, 2009, 10:25:17 AM

UMMm, Its not that same plate we use. Where did you hear that?

Sorry, they look the same and assumed it was the same. I can delete that if you need me too?

BAMF · « **Reply #26 on:** Nov 08, 2009, 02:39:56 PM »

Quote from: jon82toy on Nov 03, 2009, 10:25:17 AM

UMMm, Its not that same plate we use. Where did you hear that?

I've got no idea but they do mention on their site that they introduced Marlin to their products. Down at the bottom of the page.

http://www.datinfab.com/about-us.aspx

Gibson · « **Reply #27 on:** Nov 28, 2009, 06:52:28 PM »

well smart man but i just took away any integrity that bumper had

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