DIY HiddenFront Winch install, no welding req. with pics

[GNERGY]

I did a search and couldn't really find what I wanted, and more guys have asked about this. So I am going to do my best to give a step by step install with pics. This is on my 91 Burb. I got a Smittybuilt XRC8 at a real good price and wanted to put it behind the front bumper. I'm not a real big off roader so I figured for the money and a 2 yr. warranty and for $30.00 a lifetime warranty i couldn't go wrong. I looked at Jasons but he has a bodylift and I don't so I had to do mine different, So here we go.
Parts
Winch mounting plate # 90476-6V6A $39.99 Harbor freight
Qty 4 1/2 13x 2in long grade 5 or better plus nuts, flatwashers, lockwashers.
Qty 2 spacers 1/4in thick x 2in x 7in long or a handfull of flatwashers.
Qty 4 squarewashers 1 1/2 x 1/4in thich with a 1/2in hole.
12 ft. #1 OR #2 Welding cable
Qty 6 ring terminals to fit what size wire you use.

Cut the plate to 27 1/2 in. long, it has to be cut a 1/2 in off center because the motor is larger than the clutch side. Then you have to notch the plate to clear the rivets inside the frame. Put the plate inside the frame and use the 2 front holes in the frame for the 2 first holes you mark on the plate. Drill the 2 1/2in holes in the plate and put it back in the frame and mark and drill the the other 4 holes ( probably overkill ) but that is how many I did. I drilled them small first 1/8in. and took the plate out and drilled the frame and the plate to 1/2in then. Here are a couple pics. more instructions and pics to come.
Tarey

 

[GNERGY]

I had to make 2 spacers to clear my oil cooler lines. I needed a 1/4 inch so the spacers are 2in x 7in x1/4in thick aluminum that I had laying around. You could use a handfull of flatwashers or whatever you have, or if you don't have the oil cooler you won't need any spacers. I then put a couple bolts in the plate so I could put the bumper back on and trace the hole for the roller fairlead on the inside of the bumper. Then center the hole in the bumper and drill a hole in each corner for the sawzall to cut your hole out.
Tarey
More to come.

 

[GNERGY]

Cut the hole out and file the sharp edges. Then center the roller fairlead on the front of the bumper and drill the holes for mounting it.
Next I made a bracket to mount the solenoid control box on the drivers inner wheel well. I don't think you want it hanging off of the winch, as per winch instructions. Some guys go as far as mounting a switch in the dash to operate the winch from there. This is how I did mine, you could do yours however you want.
Tarey

More to follow

 

[GNERGY]

My instructions got ahead of my pics, got to get caught up.
Tarey

 

[GNERGY]

This is where I mounted the bracket to the drivers side inner wheel well. Just used a couple of 3/8in. bolts, and 1/4in bolts to mount the solenoid box to the bracket. The power leads to the winch are too short now, so this is where the piece of welding wire comes in handy. I cut it into 3 pieces 40in. long. Then stripped the insulation off and crimped ( using a center punch and a hammer ) the ring connectors to the wire. Then I soldered them for the best possible connection. Also heat shrinked the ends.
Tarey.

 

[GNERGY]

The box of ring connectors I got at checkers, actually needed 3 boxes which is all they had. Mark your wires 1 red 1 yellow and 1 black to replace the short ones from the solenoid box.
Tarey

 

[GNERGY]

I picked up some grade 8 bolts to replace the grade 5 that came with the winch to mount it to the plate. I used a little blue threadlocker to keep them from coming loose. You have to secure the ground cable to the winch that goes on the negatine terminal of your battery BEFORE you bolt the winch to the mounting plate. I torqued them to 35 ft. lbs. Then slide the plate with the winch attached into the frame and bolt it in.
Tarey

 

[muddybuddy]

looks sweet! ive never seen inner fenders that were that clean and rust free!

 

[Blue85]

Any concerns with smacking the winch on stuff? If the oil cooler lines weren't there, do you think the winch mount plate could go on top of the frame? How close is it to fitting with the plate bolted to the bottom of the frame (winch on top of the plate)?

 

[Kota4bye]

Pretty slick! Nice work.

 

[cegusman]

Looks clean

 

[Big Blzn]

Looks really good and a nice clean rig too. That winch mount looks pretty flimsy. Is that one of the mounts that goes onto the front of a Heep? I'm sure it has been tested and all but I just expected bigger or thicker gauge steel than what I see. Just curious is all.

 

[RockinChevy]

Saving to my folder. I'll do this to my crew cab.

 

[blazin' j]

plate thickness looks like its for a 8000lb or so winch...is that what the winch is rated for??? what brand is it??? awesome job...

 

[454k30]

Looks like 1/4 inch steel and it has a C-channel shape so it is probably pretty resistant to twisting and bending. I was thinking about going with something like this as well to avoid having a big winch hanging of the front of my truck.

Beautiful job on that install! Gives me hope.

 

[y5mgisi]

nice work for sure!

 

[blazin' j]

looks way more stealthy than mine...

and the winch may b just a "hair" smaller than mine...(16,500lb superwinch)

awesome job though for sure...man some people have some talent on here...

 

[ryoken]

the new pic whore..

I'll play devil's advocate and newbie basher..... center punch crimping?

 

[shaun89]

thats pretty sweet man. u got any pics of the whole burb? and i love pic whores! dont judge me hahaha

 

[Slapperbar]

I so need to do this to mine. I wonder if a 12K will fit.