Warn Powerplant on Marlin bumper build

[germ]

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]

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]

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

[germ]

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

[germ]

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

[germ]

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

[germ]

Side view

[germ]

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

[germ]

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

[germ]

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

[germ]

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]

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]

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.

[germ]

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]

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

[junya92toy]

Should of got a winch plate and welded in there.

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

[axled89]

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

[germ]

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]

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]

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

[germ]

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

[Volcom]

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]

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]

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]

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]

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]

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]

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