Extra thick hawse fairlead

[AAA]

Anyone know of someone who makes a hawse fairlead to fit a Warn M12000 that's thicker than 1.5 inches?
It's mounted on an ARB Deluxe Bumper 3436040bar. It's setup for a traditional roller fairlead and is recessed 3.5" deep. I'm switching this winch over to synthetic line. ARB makes a sheet metal spacer to use a hawse fairlead, but is seems like a pissweak way to do it. Anyone make an extra thick fairlead for this application, I can't be the only one looking for something like this?

 

[1911]

Solution looking for a problem? Synthetic line works just fine with a roller fairlead; been using it that way for 15 years myself.

 

[gnob]

and.

Upgrading from cable to synthetic - why keep roller fairlead?

I've seen several builds, on here and in person, that have synthetic line with a roller fairlead - like this one I have the same ARB bumper and am concerned about my winch line snagging the build in roller bracket, let alone having issues with the rollers and the line. I was thinking about...

forum.ih8mud.com

 

[Dumpolina]

Solution looking for a problem? Synthetic line works just fine with a roller fairlead; been using it that way for 15 years myself.

View attachment 3928550

Ditto
Viking!

 

[1911]

Viking!

I was sad when Thor closed his business; it was quality stuff.

 

[Dumpolina]

I was sad when Thor closed his business; it was quality stuff.

Agreed 100%

 

[AAA]

15 years and you've never had a fairlead failure? Question, have you ever had warn solenoids fail? Maybe it's just the conditions and forces involved. Whilst I hear what you are saying that has not been my experience. That might work for a smaller vehicle, but my use case is for a Ford excursion (curb weight is 8000lbs), way more that you SWB FJ40. It's also not recreational, it's to be able to get in and out of where I'm living. My life can depend on it failing.
For whatever reason, there's been many occasions where I've need to side pull. So far I've destroyed two roller fairleads where the line has wedged in the corner and bent the side roller supports. I've also destroyed two where the rollers themselves failed and seized up. One using steel cable and one using synthetic. Having the line wedged into the corner of the fairlead and been stuck in deep snow with no cell coverage and no one coming to get me is not something I'd like to experience again.

 

[1911]

15 years and you've never had a fairlead failure? Question, have you ever had warn solenoids fail? Maybe it's just the conditions and forces involved. Whilst I hear what you are saying that has not been my experience. That might work for a smaller vehicle, but my use case is for a Ford excursion (curb weight is 8000lbs), way more that you SWB FJ40. It's also not recreational, it's to be able to get in and out of where I'm living. My life can depend on it failing.
For whatever reason, there's been many occasions where I've need to side pull. So far I've destroyed two roller fairleads where the line has wedged in the corner and bent the side roller supports. I've also destroyed two where the rollers themselves failed and seized up. One using steel cable and one using synthetic. Having the line wedged into the corner of the fairlead and been stuck in deep snow with no cell coverage and no one coming to get me is not something I'd like to experience again.

Yeah, I’m sure there must be differences as you say. I have pulled some big loads with that (modified) 8274 on the 40 though- including a big diesel pickup with a loaded gooseneck trailer, uphill out of a deep ditch, and never had a roller failure or a pinched line.

I have had Warn solenoids fail, and a Chinese replacement motor fail, on this and other winches. For that reason, I replaced the solenoids with a single contactor, and the motor with a Warn 9.5XP motor that is more than double the horsepower of the original. This combo has been 100% reliable.

 

[gnob]

sounds like your options are:
build a spacer. (1.5+" isn't exactly sheetmetal imo)
pay someone to machine what you need.


actually interesting to hear the rope blew up a roller fairlead..... guy in other thread said it wasn't possible

 

[WesCadwall]

Factor 55 sells a thicker hawse fairlead but I dont know if this would help.

 

[80t0ylc]

15 years and you've never had a fairlead failure? Question, have you ever had warn solenoids fail? Maybe it's just the conditions and forces involved. Whilst I hear what you are saying that has not been my experience. That might work for a smaller vehicle, but my use case is for a Ford excursion (curb weight is 8000lbs), way more that you SWB FJ40. It's also not recreational, it's to be able to get in and out of where I'm living. My life can depend on it failing.
For whatever reason, there's been many occasions where I've need to side pull. So far I've destroyed two roller fairleads where the line has wedged in the corner and bent the side roller supports. I've also destroyed two where the rollers themselves failed and seized up. One using steel cable and one using synthetic. Having the line wedged into the corner of the fairlead and been stuck in deep snow with no cell coverage and no one coming to get me is not something I'd like to experience again.

Traveling in areas with no cell coverage is nothing new. You might consider using an inReach or similar device, satellite-based, so you can send messages or an SOS when stranded.
Edit add: Remember, nothing is completely fool proof. Having a back up plan, is always a wise decision.

 

[WesCadwall]

Yeah, Sat phone is in my kit when Im hunting, riding dirtbikes or 4x4 in remote spots. Peace of mind.

 

[PIP]

15 years and you've never had a fairlead failure? Question, have you ever had warn solenoids fail? Maybe it's just the conditions and forces involved. Whilst I hear what you are saying that has not been my experience. That might work for a smaller vehicle, but my use case is for a Ford excursion (curb weight is 8000lbs), way more that you SWB FJ40. It's also not recreational, it's to be able to get in and out of where I'm living. My life can depend on it failing.
For whatever reason, there's been many occasions where I've need to side pull. So far I've destroyed two roller fairleads where the line has wedged in the corner and bent the side roller supports. I've also destroyed two where the rollers themselves failed and seized up. One using steel cable and one using synthetic. Having the line wedged into the corner of the fairlead and been stuck in deep snow with no cell coverage and no one coming to get me is not something I'd like to experience again.

I have been involved in the manufacture of roller fairleads. There's a pretty big difference between some and most are real junky. Stainless ones are especially junky.

I sold a few thousand leftover roller fairleads from a military contract on Amazon for $50 each. They had a 1/4" A514 frame, 7/16" thick rollers with oilite bronze bushings and 35RC 4140 pins.

No way you're bending one of those. Kept a few for myself and the rest are long sold out. Took me 7 years to sell them all. Nobody seems to care about good quality roller fairleads. So you get a lot of junk. People can't tell the difference I guess. A decent roller fairlead weighs 20 lbs.

Hawse fairleads are funny. $10 in aluminum, $10 in machine time and $4 in anodizing. Can't believe what some are charging for such a simple part.

 

[aztoyman]

I would have bought one of those fairleads @PIP if I had been aware of them back when you were selling them. EVERY roller fairlead that I've had was either an abused old Warn or the really flimsy ones common today.