Defender Winch Bar, Got 3 days to spare?

**sclarke** · 16th April 2007, 05:05 PM

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.

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.

Then i welded it all up and here is one of the SPECIAL welds......

Ohh and a pic before i welded it up.....

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** · 17th April 2007, 07:29 AM

Tasty!

**sclarke** · 17th April 2007, 05:07 PM

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....

**fossil** · 17th April 2007, 05:15 PM

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

Iain

**spudboy** · 17th April 2007, 05:17 PM

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** · 17th April 2007, 05:18 PM

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** · 17th April 2007, 05:21 PM

Originally Posted by 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....

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

**100I** · 17th April 2007, 05:37 PM

Originally Posted by sclarke

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

you know it's still crooked, right?

**sclarke** · 17th April 2007, 05:40 PM

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** · 17th April 2007, 05:42 PM

Originally Posted by 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.

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

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Defender Winch Bar, Got 3 days to spare?

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