Bought a winch bar, need some ideas!

[LRJim]

Hey All
So I scored this winch bar off scumtree last night. I paid 230 clams for it so I'm pretty happy with myself!
It looks to be nice and solid been repainted a couple of times but still looks decent. Plenty of mounting points for antennas and lights, a few recovery points, washers and indicators/parker lights.
I don't know what brand it is maybe someone here will have an idea. It looks to be modified as it dosnt have any sides under the fenders, or maybe it's from a RRC? I may neaten the sides up see how it works with flares.
The only issues I have are that it dosnt have any mount for the winch, I have no dramas fabbing one up but some ideas would be great!
The mounts don't look strong enough for a recovery situation and the bolts are thin so I'm gonna make mounting plates and get some thicker bolts.
And it dosnt look very legal on the front it's got that leg breaker bar on the front. I'm hoping it's because it's an old bar and the rules changed in 95 for cars made after 95 (vic).
If anyone's got a few photos of their winch mounts that would be good.

Also the last image is from gumtree, I couldn't help myself with the oil stain!

Cheers Jim https://uploads.tapatalk-cdn.com/20180905/df46aaa987be52458d565b3d14663dc2.jpghttps://uploads.tapatalk-cdn.com/20180905/14b0f3aea9a0724de736ac6c36caa582.jpghttps://uploads.tapatalk-cdn.com/20180905/46526f356f02a879ff2c9f8784be185e.jpghttps://uploads.tapatalk-cdn.com/20180905/a4c6c1ddcefab6fc5f07a1e834ee4e43.jpghttps://uploads.tapatalk-cdn.com/20180905/77786148dbf6b91581d940a0fd7e009d.jpghttps://uploads.tapatalk-cdn.com/20180905/9d26a866bf501a648eaa71d089414a2e.jpg

[DAMINK]

I made a box out of 6mm steel and then welded it into the bullbar.

Here is one image. I only have a couple but can get more if you need.

143965

The focus was on my arc welds.... cause they were sexy hahaha but to the left if the box, to the right of the welds is where it fits to the chassis. Not a great pic though as i said but a 6mm box will do the job.
I tested mine recently and it worked perfectly. I did also add crushing tubes to the chassis for the third bolts as mine only had crushing tubes on the front 2 bolts.

143966

They were later cleaned up and washers welded to give the correct spacing.

143967

Cheap and easy lol. Yea im a backyarder but it is what it is.

For me though the most important was trying to get the bullbar to actually tighten up strong enough to the front rails so i was happy. It had to be the 3 bolts even though the third one is not a factory bolt hole.

For me it was a fun job actually.

[rangieman]

You can fit a high or slow mount on that bar [bigrolf]
The winch bolts directly to the bar [bighmmm]
No winch mount needed[wink11]

[DAMINK]

You can fit a high or slow mount on that bar [bigrolf]
The winch bolts directly to the bar [bighmmm]
No winch mount needed[wink11]


The bar only has 2 bolts holding it to the chassis. That bothers me.
Actually being an open bottom bar that bothers me also. Weld in a bottom and it will strengthen the bar a **** load.

[LRJim]

You can fit a high or slow mount on that bar [bigrolf]
The winch bolts directly to the bar [bighmmm]
No winch mount needed[wink11]I thought that was the case but were lol
I can't work out how to mount the one I already have, it's not here so I can't take a photo. It's like a 16k lb Chinese one that bolts on from underneath. I've only used it on a tray before. And the last 4x4 I had already had one mounted. It looks like there's no were to mount this type. I must be thinking about it the wrong way lol.
Cheers Jim

[DAMINK]

I thought that was the case but were lol
I can't work out how to mount the one I already have, it's not here so I can't take a photo. It's like a 16k lb Chinese one that bolts on from underneath. I've only used it on a tray before. And the last 4x4 I had already had one mounted. It looks like there's no were to mount this type. I must be thinking about it the wrong way lol.
Cheers Jim

Just like mine. It bolts to the bottom thus the box i made.
Some are better and can be bolted sideways and you move them to suit. But cheapy ones only bolt at the bottom or so it seems.

[LRJim]

For me though the most important was trying to get the bullbar to actually tighten up strong enough to the front rails so i was happy. It had to be the 3 bolts even though the third one is not a factory bolt hole.

For me it was a fun job actually.

Yeah like I said im not real happy with the mounting. Defiantly needs the 3rd bolt and much thicker bolts. I wanna make a couple of brackets/recovery points to help beef it up a bit. I gotta go to ballarat to to get the bloody winch from my block so the fun dosnt start yet :( I threw it on at 9 last night I was that keen hahaha

[DAMINK]

Yeah like I said im not real happy with the mounting. Defiantly needs the 3rd bolt and much thicker bolts. I wanna make a couple of brackets/recovery points to help beef it up a bit. I gotta go to ballarat to to get the bloody winch from my block so the fun dosnt start yet :( I threw it on at 9 last night I was that keen hahaha

Yes mate i thought the exact same thing. Cut out a hole in the bar and make recovery points that weld into the mounting point the the chassis.
I just dont trust my welds enough to do that though. Im worried enough with my winch! But if i kill someone by having a weld break i could not live with myself.
Dunno man i drew the line in the sand there. I will weld up bullbars etc but not towbars or recovery points. I will weld draw bars on trailers so i dunno.....

[LRJim]

Yes mate i thought the exact same thing. Cut out a hole in the bar and make recovery points that weld into the mounting point the the chassis.
I just dont trust my welds enough to do that though. Im worried enough with my winch! But if i kill someone by having a weld break i could not live with myself.
Dunno man i drew the line in the sand there. I will weld up bullbars etc but not towbars or recovery points. I will weld draw bars on trailers so i dunno.....Yeah I definitely hear where your coming from it's good to draw the line somewhere. I was more so thinking cutting and shaping some 20mm plate and bolting it through the 2. Like a bolt on recovery point you can buy but made to do the 2. I'm not keen on doing any welding on the chassis anyway I only stick weld i probably could get way with thin rods but it's not worth ****ing with just it case. I stick weld on the series chassis but that's a different kettle of fish.

[DAMINK]

Yeah I definitely hear where your coming from it's good to draw the line somewhere. I was more so thinking cutting and shaping some 20mm plate and bolting it through the 2. Like a bolt on recovery point you can buy but made to do the 2. I'm not keen on doing any welding on the chassis anyway I only stick weld i probably could get way with thin rods but it's not worth ****ing with just it case. I stick weld on the series chassis but that's a different kettle of fish.

Yea i see what your saying. Solid piece of thick metal lets say 12mm or so and cut it so it bolts onto the rails either side...... Hmmmm i like your thinking mate.
I know what im making tomorrow :)

[LRJim]

Yea i see what your saying. Solid piece of thick metal lets say 12mm or so and cut it so it bolts onto the rails either side...... Hmmmm i like your thinking mate.
I know what im making tomorrow :)12mm should definitely be enough might be worth looking up bolt on recovery points even on eBay and look at the specs 1st and work off them as a basis. I look forward to seeing your brackets then I will have something to copy off :) I was thinking even a H shape on cut from some scrap. That way you have a flange underneath the chassis, one on each side for the bull bar bolts and then you will be left with a piece hanging down to drill holes for recover points. Hard to explain withought a sketch

[Tins]

Not 100% sure, but I have never seen a D1 winch bar. The D1 used a cradle mounted behind the bar, bolted directly to the chassis. As I said, not 100%, maybe it was the airbag models, but most D1 bars I have seen have deformable 'crash cans' to mount the bar to the car, and of course they don't cope with winches.
Even if yours is earlier, I'm tipping if you can fabricate, a chassis mounted cradle is a better bet.

I'd be happy to take a pic or 2 of mine if it helps.

[trout1105]

I have an ARB winch/bull bar fitted to my D2a an it uses crash cans to mount to the chassis with 6 bolts.
I have used my 1200lb winch on many occasions and have done No damage whatsoever to the crashcans.

[DAMINK]

Just something to be aware of.

If you make a bottom plate to mount your winch you will find it hard if not impossible to fit the winch with the bar on the car.
No big deal infact it makes it safer so no sticky fingers will try steal it. But it does make the job a little more difficult having to lift the bar and winch all together.

Another thing. Looking back at those pics, i would be looking to weld some sides to the bar to make it flow with the guards instead of the way it sort of cuts off.

[LRJim]

I honestly don't like the idea of winching off the bar anyway. Sure they could handle it but chassis is best in my eye, you wouldn't snatch off a bullbar (yes there's like 3 times load the on the snatch) and a winch can get some tension on it.
The original bumper had the crush cans but I honestly thought the chassis rail would have them built in being an airbag model.
I know the bullbar isn't an airbag one so I'll probably disconnect the 21yr old airbags I wrote about it in my other thread.
Making a cradle mounted to the chassis is what I'll definitely be doing there's plenty of room there.
I think I may have to cut the pointy bar off at the front I will probably get a fine with it. I have no idea what it's for either something for the winch wire to rest on or it just helps with impacts especially cyclists lol
Cheers Jim

[LRJim]

Just something to be aware of.

If you make a bottom plate to mount your winch you will find it hard if not impossible to fit the winch with the bar on the car.
No big deal infact it makes it safer so no sticky fingers will try steal it. But it does make the job a little more difficult having to lift the bar and winch all together.

Another thing. Looking back at those pics, i would be looking to weld some sides to the bar to make it flow with the guards instead of the way it sort of cuts off.I think I may be able to drop the winch in from above there is a pretty big hole, but I'll have to take the bar off to fit the cradle anyway so yeah no big deal.
I think it had the sides originally it looks to have been cut and welded like that but it could be wear and tear. I will make something for the sides but I may buy some flares 1st and work it in with them.
Ive already damaged my rear guards a bit with 32 tyres and no lift the front rubs a bit also but the back is really bad. Lucky the tyres were already on the wheels I paid 150 for them, their were already at the end of their life.
Did you think about your support plates last night?

[Rick1970]

Pointy bit on the front of the bar will add a considerable amount of strength to the bar for winching, its there for a reason.

Watch length with a 16000lb winch, bar i made for my V8 D1 has a 9500lb Premier winch mounted in close between the rails, and only just fits length wise. I wouldnt have 5mm clearance.

[AK83]

I may be wrong about this(not unusual), but I reckon the bar is for a defender, not disco .. hence why no side returns for the front guards.

It obviously fits, so no problemo.

[Rick1970]

I may be wrong about this(not unusual), but I reckon the bar is for a defender, not disco .. hence why no side returns for the front guards.

It obviously fits, so no problemo.

Old ARB himount winch bar for a RRC would be my guess...

[Rick1970]

Fit the missing mounting bolts (should be 6, not 4...1/2" UNF???), bolt winch in using 4 of the six mount holes on front face (as long as your winch has a std mount patern, may have to rotate motor and/or gearbox to suit), wire up and your good to go.

Mr rego man may have a different view if its a non SRS bar mounted to a SRS equipped vehicle.

[LRJim]

Old ARB himount winch bar for a RRC would be my guess...My money is on RRC also but the sides look rough like someone has chopped them and re welded them like that. Maybe an early D1? Either way same chassis so she fits! Need HD springs at the front now lol

[LRJim]

Fit the missing mounting bolts (should be 6, not 4...1/2" UNF???), bolt winch in using 4 of the six mount holes on front face (as long as your winch has a std mount patern, may have to rotate motor and/or gearbox to suit), wire up and your good to go.

Mr rego man may have a different view if its a non SRS bar mounted to a SRS equipped vehicle.From memory it's a bottom mount winch it's just a cheapy Chinese one, It was for my old f truck. And I'm gonna buy new bolts all round there just the original bumper ones.

And Mr rego man won't know unless I go for a RWC. I'm probs gonna disconnect the bags anyway there old as ****

[Rick1970]

From memory it's a bottom mount winch it's just a cheapy Chinese one, It was for my old f truck. And I'm gonna buy new bolts all round there just the original bumper ones.

And Mr rego man won't know unless I go for a RWC. I'm probs gonna disconnect the bags anyway there old as ****

Check the mount pattern, std is 10" x 4.5". This face goes against front face of bar, motor and gearbox should be able to be indexed to get the clutch lever and terminals into a workable position. Most winches can be mounted bolt face down, or bolt face forward. Design of the bar usually dictates mounting orientation.

[AK83]

Old ARB himount winch bar for a RRC would be my guess...

Aha!
I can't remember the exact design shape of my old RRC bullbar, but I think it had the wrap around ends. Wasn't ARB I don't think, wasn't a homemade jobbie, but was a very sturdy aluminium.

[DAMINK]

Check the mount pattern, std is 10" x 4.5". This face goes against front face of bar, motor and gearbox should be able to be indexed to get the clutch lever and terminals into a workable position. Most winches can be mounted bolt face down, or bolt face forward. Design of the bar usually dictates mounting orientation.

Some of the cheapy ones can only be bottom mounted and i think the OPs one is a bottom mount so turning is not an option.
Similar to mine actually.

Given that it needs a base to sit on. Get welding son [thumbsupbig]

[LRJim]

Some of the cheapy ones can only be bottom mounted and i think the OPs one is a bottom mount so turning is not an option.
Similar to mine actually.

Given that it needs a base to sit on. Get welding son [thumbsupbig]Gotta drive out to ballarat to get the damn thing 1st! It's been used to drag logs around at my block I rigged up a mount that slots into my towbar. I havnt gone up for 6 months now so it's a good excuse to go.
I also need to buy some rollers and remote, I've had 2 wires pushed in the sockets that I've been using to control it haha