I've been working on a way to mount a Warn winch without it protruding off the front end like a wart. I also wanted to maintain a mostly stock appearance with the front bumper. After seeing a couple of bumper builds on this forum I decided to trim the front cross member and tuck my Warn M8000 winch back as far as possible without interfering with the Harmonic Balancer.
I trimmed the cross member:
Wrapped both rails:
Added the Winch Plate. Fabbed and painted:
I also upgraded with a Dodge durango steering Box:
Mounted the fairlead roller:
Finished: Tucked and Trimmed
The relay box is under the passenger fender, just to the side of the winch. I also installed a cabin switch panel with an airplane safety switch and a rocker to play out or take in line. As well as a master power shut off for the winch near the battery.
I'm really happy with how it came out. I've improved my welding (and grinding) skills. I'm planning on attaching my front license plate to the roller assembly, but haven't worked it out yet. I'll be trimming up the bumper edge with door trim to clean it up.
Thanks All, I'm really satisfied with how it turned out. I appreciate the accolades.
I'm not sure this could be done on a production basis, based on the tight space and tolerances. There were a number of customizations that had to occur to make this fit. The final unit with the winch plate was a very tight fit and took a sledge to get on/off for final tweaks. A simple U-shaped winch plate would have sufficed. with much less trimming, but I tend to over-build everything. If Detours or others think it can be done than go for it, with my blessing!
Here is my Winch Master Power Switch. It's attached to the A/C bracket near the battery:
I also installed my switch panel, the middle safety switch turns the winch controls on/off, the rocker takes in/plays out line. The other safety switch powers my Methanol Injection, more on that later:
I have also clocked the winch to point the clutch knob at the bumper instead of straight up. I'll be punching a hole in the bumper so I can turn it with a screwdriver.
@dcorn, I saw the hawse fairlead but wanted the roller type. You are correct, they take up less space but are not as effective in reducing wear on the winch line. I also wanted to stay with the cable vs. rope. Rope is affected by UV rays and can also be welded together if you have a long, hard pull. The worst that can happen to cable is it can kink.