Trailer Winch Sizing **Building the "Tugger Box"**

[TerryD]

I have a tag along trailer that I'm wanting to put a winch on. It's a low boy we use to haul vehicles on and has two 3500lb axles with a single braking axle. I'm torn between getting a 3500lb winch and a snatch block or getting something closers to the trailer's rating and having the ability to double that with a snatch block.

We've used a manual come along till now and I'm getting tired of cranking on that thing. Having to haul the Xterra home a few months ago got me thinking about how nice it would be to be able to just push a button and pull something up.

 

[skunked]

just went through a similar scenario with the box trailer, chose the 5k simply because it was only a few bucks more.

 

[obijuank5]

Will you be pulling up a dead rock crawler with a broken knuckle or something with much less resistance.
5k generally will do most anything that rolls ok.

 

[TerryD]

Will you be pulling up a dead rock crawler with a broken knuckle or something with much less resistance.
5k generally will do most anything that rolls ok.

I will be hauling the K5 on it so that's entirely possible.

just went through a similar scenario with the box trailer, chose the 5k simply because it was only a few bucks more.

That's what I've been thinking as well. A couple bucks almost doubles the capacity plus I've considered swapping in a pair of 7k axles if I can find them.

I've also got to figure out how to enclose and protect the winch since it sits outside all the time.

 

[skunked]

My flatbed has a warn 8274 on it and they make winch covers for them that strap over it. When it's being stored I flip a Tupperware container upside down over it to keep it out of the weather.

 

[Capt Ron]

I went totally overkill, 8000# Ramsey purchased at a swap meet for $200.00. I do not regret it a bit .It pulls full size trucks with flat tires / broken suspensions on with no problem.
Whatever winch you choose I would try to mount it as low as possible.

 

[yellowK20]

Not really a winch size recommendation , but buy one of those tool boxes that are designed to go on the tounge of the trailer and mount the battery and winch inside it so they are more secure ,

 

[skunked]

Those tongue boxes are great, I have one on the flat bed that houses my battery, straps and misc tools. Bought it at harbor freight.

 

[ktmoutfront]

Just a plastic large box at the front on the deck works to enclose a winch also.

I picked up a 9500 XRC winch at 4WP grand opening for $250.

 

[kgblazerfive]

I have a Harbor Freight for mounting on my trailer when ever I get one.

 

[TerryD]

Gonna just bump this up.

I walked into Tractor Supply a few weeks ago and they had a stack of winches on sale for insanely low prices. I mulled it over really quick and grabbed a 4500lb Traveller (store brand) ATV winch for $40 (yes, $40). Now I've been thinking on this project for a while now and I've decided that I wanted to build something portable. I had considered one of the Superwinch box winch setups but hadn't pulled the trigger yet. Since I got such an amazing deal on this one, I've set to building my own setup. I've lovingly dubbed it "The Tugger Box."

First was to find a tool box. I couldn't find a plastic box that suited my needs. While, browsing at Hazard Fraught the other day, I stumbled on this nice metal tool box for $26. With 25% off for Labor day, it was right around $20 out the door. I also grabbed a cheapo shackle mount and a 2" ID receiver tube while I was there.

20180901_170138 by TerryD, on Flickr

I came up with a scheme for mounting it where I can use it strapped to a tree, in a receiver tube on my truck or even in receiver tubes I'm going to weld to my trailers. Using the 18" receiver tube from HF (actually 17.5" long), I sawed 5.5" off to make a tube for my flat bed trailer and used the remaining 12" under the mount plate that came with the winch. I then marked and drilled holes in the tool box to mount the plate and fairlead to the outside of it. I drilled another 11/16" hole in the receiver tube to accept a shackle mount on either end. The larger shackle mount can be reversed in the Tugger's tube and used in a vehicles receiver or in the tube I'll weld to the trailers later. It can also be used with a tree saver and the shackle. The smaller HF shackle mount on the front will be for using a snatch block to get 9K worth of capacity should I need it. I'm also going to add heavier duty handles to the body of the toolbox rather than rely on the chincy one on top and the light duty latch.

20180907_134233 by TerryD, on Flickr

20180901_184236 by TerryD, on Flickr

I've ordered a set of 25' long, 4ga jumper cables to make the power feed out of. They are long enough to stretch the lenght of my K2500 from the battery to the back bumper where I can operate the winch. I may do something different in the future, but for the time being I think these will do ok. There should be enough room inside the Tugger Box to store the cables, a 10k snatch block, a couple shackles and a tree saver. With this setup, it can be used with my lawn tractor, daughter's 4 wheeler, my Xterra and pickup or basically anything around the house.

In the future, I may swap out the wire rope for synthetic and a Hawse fairlead, but I doubt it.

 

[TerryD]

I managed to get the frame pieces welded together after work this evening and get it assembled. I used some blue lock-tite on the bolts that hold the winch to the frame. Here it is assembled:

20180911_195243 by TerryD, on Flickr

20180911_195309 by TerryD, on Flickr

20180911_195343 by TerryD, on Flickr

And the tray still goes in above the winch to hold the shackles and snatch block:

20180911_200012 by TerryD, on Flickr

My 25' jumper cables should be here tomorrow so I can get the controller wired up and it'll be ready to use. If it's not pouring rain, I'll set it up and respool the cable. When I took the rubber band off the cable to put the hook on it, it all loosened up on the drum. Now it's time to get started on the big trailer. I've got a few boards to replace on it and weld on the receiver tube to accept the box.

 

[TerryD]

Test run complete! I had to rework the switch wiring to get those 4ga lugs landed on it but it works properly. We unspooled it and then wound it in under power, pulling my wife through the yard.

My truck is out getting inspected or I would have towed the Xterra up to it.

 

[TerryD]

Finally got the trailer refloored. I've still got to add the receiver tube to the front of the trailer so I can mount this when it's needed. I've also got to get the trailer repainted. It's looking pretty rough and I noticed some rust holes in my fenders. Hopefully I can pull the wheels and pressure wash it soon and have the kids paint it.