Defender Winch Bar, Got 3 days to spare?

[sclarke]

Guys,
Got excited this morning and started my Winch bar.
Its bassed on the Tubular style that is Avail from Equipe

But i've made it from scratch with no plans and all from my head.
I changed it 3 times during the day and so its taking far longer than i wanted....

The only thing it had to have was the same or better approach angle as the Std Bar.

OK..
Details all made from 6mm plate in various shapes and angle thingy's

I started by drilling the Base plate and mounting it 1st. Its a 200mm wide sheet.
https://www.aulro.com/afvb/images/imported/2007/04/248.jpg


Then i made the Side supports. These were a bit tricky. I used the existing Chassis holes and also added 1 more on each side above the Tie down mounting hole. These have to have a slot so they can fit around the chassis parts that stick out.
https://www.aulro.com/afvb/images/imported/2007/04/249.jpg

Then i welded it all up and here is one of the SPECIAL welds......
https://www.aulro.com/afvb/images/imported/2007/04/250.jpg

Ohh and a pic before i welded it up.....
https://www.aulro.com/afvb/images/imported/2007/04/251.jpg

Something to ponder.
Winches can be mounted to the base plate, or front plate or the top plate or the rear plate..... the motor and gearbox needs to be adjusted to suit, but thats cool...
So i'm mounting mine to the base plate and having the front plate with only the Fairlead rollers attached.
I thought hard about this and the result was to mount it to the base plate as it has a greater strength than the front fairlead plate. It has bolts holding it directly and the welded side plates. If i mounted it to the front plate, then i would only have the strength of the welds to hold it in place.

Tommorow i'll make the rest and if all goes well get it painted....
Love holidays.....

Clarkie

[MacMan]

Tasty!

[sclarke]

OK i lied.....
2 days to build it....... not 3....
so at my rate of $60ph... that with materials comes to..... about $1400
Hell i could have bought a professional one for that......

OK,
Here is what i did......
Welded in the sides and trial fitted the winch....
https://www.aulro.com/afvb/images/imported/2007/04/218.jpg
https://www.aulro.com/afvb/images/imported/2007/04/219.jpg

Then i welded in the Front panel.
https://www.aulro.com/afvb/images/imported/2007/04/220.jpg

You can see where the winch bolts.... to the base plate not the front.
https://www.aulro.com/afvb/images/imported/2007/04/221.jpg

Then i added some sexy side arms.... Mmmm Nice...
https://www.aulro.com/afvb/images/imported/2007/04/222.jpg
https://www.aulro.com/afvb/images/imported/2007/04/217.jpg

Getting them exactly square to the body lines and the front panel was a PITA.....

Then a Trail fit of all the bolts and the winch and the fairlead....
https://www.aulro.com/afvb/images/imported/2007/04/213.jpg
https://www.aulro.com/afvb/images/imported/2007/04/223.jpg

Then i pulled it off and painted it.
https://www.aulro.com/afvb/images/imported/2007/04/224.jpg
https://www.aulro.com/afvb/images/imported/2007/04/225.jpg
https://www.aulro.com/afvb/images/imported/2007/04/226.jpg

Tommorow i will fit it all up and jump for joy....

Ohh the weight of it...........

With Std springs.
It dropped 5mm with the weight of the bar and no winch. that was measured when no bumper was the guide line.
My guess is it weighs about the same as an Alloy bull bar..

Dont ask me to build you one..... it takes way to long and its not an easy job. i destroyed 2 angle grinders... NEW ones also... Bunnings hates me....

[fossil]

Looks real good. The round tube under the winch base plate, are they high lift jacking points?

Iain

[spudboy]

Good work.

How did you get your metal pieces cut so nicely? Just with an angle grinder? Did Bunnings have to replace a worn out one under warranty?

[Mick-Kelly]

I wont ask you to build me one.............great job by the way.......but i will ask if you have templates, measurements etc. Would make an excellent tutorial project. And again very well done, nothing quite like a sexy winch bar.

[ladas]

OK i lied.....
2 days to build it....... not 3....
so at my rate of $60ph... that with materials comes to..... about $1400
Hell i could have bought a professional one for that......

OK,
Here is what i did......
Welded in the sides and trial fitted the winch....



Then i welded in the Front panel.


You can see where the winch bolts.... to the base plate not the front.


Then i added some sexy side arms.... Mmmm Nice...



Getting them exactly square to the body lines and the front panel was a PITA.....

Then a Trail fit of all the bolts and the winch and the fairlead....



Then i pulled it off and painted it.




Tommorow i will fit it all up and jump for joy....

Ohh the weight of it...........

With Std springs.
It dropped 5mm with the weight of the bar and no winch. that was measured when no bumper was the guide line.
My guess is it weighs about the same as an Alloy bull bar..

Dont ask me to build you one..... it takes way to long and its not an easy job. i destroyed 2 angle grinders... NEW ones also... Bunnings hates me....

Can you build me one ;) :D :D :D

[100I]

https://www.aulro.com/afvb/images/imported/2007/04/217.jpg

Getting them exactly square to the body lines and the front panel was a PITA.....

you know it's still crooked, right?

[sclarke]

I will take measurements and post them.....
might even get exited on autocad.....

The hard part is getting the side bars on the right angle....
1st is easy... 2nd one to match the 1st... ahhhhhh bastard....

i'm going to change it a little after the trip im doing this weekend.
Spot light mounts and a hoop over the winch

Ohh a note.... it has been designed for a Slowmount, But i factored the possibility that i will get a 8274 high mount... and yes it will fit after i cut the grill and pull the AC out....

[EchiDna]

I wont ask you to build me one.............great job by the way.......but i will ask if you have templates, measurements etc. Would make an excellent tutorial project. And again very well done, nothing quite like a sexy winch bar.

all of the above... plus do you offer welding lessons? :)

[sclarke]

you know it's still crooked, right?

Yes... as is every Defender........:o :o
Accually the Left side is...and i was not kicking my leg to the right when i poked my tongue to the left at 5 deg, whilst welding

[100I]

no but i heard the fuse go from here. picturing Basil Fawlty bouncing on his on his haunches...

[sclarke]

Final pix.

Bar installed
https://www.aulro.com/afvb/images/imported/2007/04/207.jpg
https://www.aulro.com/afvb/images/imported/2007/04/208.jpg

Winch installed
https://www.aulro.com/afvb/images/imported/2007/04/209.jpg
https://www.aulro.com/afvb/images/imported/2007/04/210.jpg
https://www.aulro.com/afvb/images/imported/2007/04/211.jpg

And finally the Whole thing sitting proud on Simex ET's
https://www.aulro.com/afvb/images/imported/2007/04/212.jpg

The total suspension sag with the weight of the bar and winch. 10mm
That has been fixed by me fitting some 110 HD genuine coils (NRC9448)
Now it sits 55mm higher than std.

Bring on Friday............

[sclarke]

OK........
Here are the pix i took today...

Looking SWEEEEEEEEEEEEEEEEEETA

https://www.aulro.com/afvb/images/imported/2007/04/178.jpg
https://www.aulro.com/afvb/images/imported/2007/04/179.jpg
https://www.aulro.com/afvb/images/imported/2007/11/361.jpg

Now for the play test tommorow.....

[EchiDna]

pedantic I know - but it obscures the numberplate a lot...

all round - a great job :)

[sclarke]

pedantic I know - but it obscures the numberplate a lot...

all round - a great job :)


Ahhhhh there is a fix for that...
The slim line plate i have ordered and i'll be mounting it on the the LH side...

[Lucas]

[QUOTE=sclarke;522694]I will take measurements and post them.....
might even get exited on autocad.....

I would also be interested in specs, I will see how much to get a few sets of parts lazer cut.

[Grimace]

Hey i like it, but just for sum constructive chritisism (sp?) and to give other people ideas I have attached the following ;)

EDIT: note the text at the bottom is simply suggestin you fill in the two marked spots (stoopid paint always ruins stuff when converting from bmp) Also could even consider filling in all across the bottom to help slide the bar over the tought stuff ;)

[Ken]

Nice one mate (I really need to finish mine eh) :D

[sclarke]

Hey i like it, but just for sum constructive chritisism (sp?) and to give other people ideas I have attached the following ;)

EDIT: note the text at the bottom is simply suggestin you fill in the two marked spots (stoopid paint always ruins stuff when converting from bmp) Also could even consider filling in all across the bottom to help slide the bar over the tought stuff ;)


Hard to see, but if you cut the top 2 pieces off then you have no place to mount the lights, i am mounting my lights on them and then they are still above the Winch, if you cut the pieces then the free spool leaver and the top of the winch will hit the light brackets.

You cant fill the bottom part in. if you do you can get to the mounting bolts and the recovery hook bolts. Thats why i did not do it....

Steve

[barryj]

Nice job, and just to prove it's on an authentic Land Rover ....... oil on the driveway :D.

[Snapper]

Top Job.

What tyres are they?

[sclarke]

Top Job.

What tyres are they?

Simex ET's

[weeds]

hey clarkey, hope you have not copy righted your winch bar yet

i will soon have a pto winch and am currently deciding wheather i use/modify my tjm bar or build one to suit it

will have to wait till i have it in my hot little hands and make a discision

[Outlaw]

got a great suggestion for you Weeds.... make a new one similar to clarkey and as you're doing one you might as well do 2 and i'll be glad to buy the second one off you :D

[sclarke]

Due to the politics of the Forum all of my material has been copyrighted......































Yarrrrr Right...

Copy away lads....