Toyota FJ Cruiser Forum banner
Cancel
Create thread New Garage Forums

Open source "hidden" winch bracket

Jump to Latest
83K views 90 replies 55 participants last post by  vanchoo954  
#1 ·
At the moment there are not too many options available for mounting a winch in the original bumper. Since I'm based in Saudi Arabia, the few options available were well out of reach. So I decided to design a winch mounting bracket myself. The taking of the measurement took several weekends before fabrication started. As it was quite some work to get a proper fit, I want to share this knowledge with the rest of you. The drawing was originally made in Autocad and was updated "as-built" after completion of the installation. It will fit as is, but I hope to see improvements published (that's why it's open source). Anyone wanting the cad file, pls send me a message.

A couple of notes:
The entire bracket is fabricated from 6mm plate, so no additional braces or brackets are necessary. The fairlead is on top of the bumper with two metal spacers (no ugly cutting of holes). The AC line only needed to be bent very very slightly (nothing to be upset about). The bottom bumper mounting brackets were trial and error and need design improvement. Some bolts on the inside of the bumper were rubbing on the bracket and need trimming. A small notch was taken out of the bottom plate to allow operation of the clutch (shown in one of the pics).

The setup was tested in the mighty Rub Al Khali (aka Empty Quarter) and proved sturdy and effective

Image

Image

Image

Image

Image

Image

Image

 
#6 ·
TOY2G said:
A couple question...

How do you access the plug for the controller?
Click to expand...
X2 I would think it would be pretty hard to get to the plug.

Do you have a wireless winch controller?

How is the fairlead bolted to winch mount?
 
Save
Reply Quote Like Like
#5 ·
Wonderful work! Looks great! The only suggestion I would have, is, being from upper central part of the US. (As other parts of the world) we have a lot of rain and snow.
You may want to add a couple of holes for drainage on the ends....

Other than that, LOOKS GREAT!
 
#7 · (Edited)
Well, thats correct, the ironman winches come with a wireless controller as standard. However, I tried to plug in the manual controller reaching in between the grille and the rediator, and was able to plug it in. Obviously the control box could mounted in a different location if required.

Weight of the bracket is around 20-22kg.
 
#9 ·
You have a very nice looking design. well done Sir. Have you done any research on the effect of the airbag system?
 
Save
Reply Quote Like Like
#12 ·
Air bag system is based on deceleration not on impact.
 
Save
Reply Quote Like Like
R
#22 ·
Looking very good. this is only one topic i can find with "open" winch bracket project. I'm glad to buy it officialy from Locust or similar but logistic to Kazakhstan is very high and much easily to build it here. Can i ask the owner of this idea, dear Mikevd, send me a CAD file to email ? Thank you in advance.
 
#23 ·
Thank you so much for sharing you knowledge and measurements! I am designing a bumper as well. But I don't have enough time to take the factory bumper on and off for measurements as it's my daily driver. I was painfully doing measurements through the small gaps. But with your info it makes my life much easier. Here is what I have so far. (And yes, I am obsessed with holes lol)
 

Attachments

#25 ·
Those are impressive 3d drafting skills. Looks like a solid bumper. It's also going to weigh at least double of my setup. You might want to consider adding some mounting bolts behind the Original crumple zone attachment point (the two times 4 bolts), as this plate is only about 3mm thick. Google for the ARB Bull bar fitting instructions to have an idea of the additional mounting bolt positions.

Good luck with the fabrication of your bar.
 
#31 ·
#33 · (Edited)
delete
 
Toyota FJ Cruiser Forum
posts
3.8M
members
129K
Since
2005
A forum community dedicated to Toyota FJ owners and enthusiasts. Come join the discussion about performance, accessories, mods, troubleshooting, maintenance, and more!
Full Forum Listing
Explore Our Forums
General Discussion Introductions & New Arrivals Interior / Exterior Visual Tech Want to Sell (FJ Related Items) Stereo / Electronics / Electrical