Undercover Winch

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PhatFJ

PhatFJ

10 Year 15 Year
Joined
Apr 20, 2008
Threads
11
Messages
64
Location
USA
So, after looking around. I could not find a good write-up on or someone offering a good hidden winch mount for the GX. So this is my solution to hiding my Warn 9.5Ti on a 2004 GX470. I am not sure how other winch's will fit, but you can take the measurements from this winch and apply them to your own. I was surprised on how much room was available behind the bumper cover. My welding skills are not great but the welds have good penetration and I have never had a problem yet (knock on wood). I am not going to go through removing and installing the bumper skin as it is straight forward and only takes about 15 minutes.

Here is the bumper after it has been removed from the vehicle, I did not remove the two extensions that mount to the frame as they will be an integral part of the winch mount.
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Here is the GX with the bumper removed. I gently bent the AC lines back towards the bracket and cooler. Just use common since and do not kink the lines.
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The bumper is made of what seems to be spring steel of some sort. When I notched the upper channel it sprung apart enough that it would not fit the mounts. I just used a ratchet strap and pulled the posts back into alignment. I then tacked in a 1/4" cold rolled steel plate, keeping the straight edge of the plate to the rear and using the bumper as a guide for the radius of the front edge. Here you will see the bumper with the plate tacked and put back on the mounts for a test fit. You will need some clamps to hold the bottom support up to the 1/4" plate for tacking.
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Here is the bumper with the winch set in place to check for clearance. I was amazed at how well it fit.
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Here is a shot looking down from the top where there is plenty of room to reach the control lever and plug in the remote.
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I will continue is the next post.
 
Here is the bumper with the plate welded in place, I closed in the ends of the upper channel that was cut with 1/4" pieces of plate. I also notched the plate for the inside mounting bolts and nuts.
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Here is a shot of the underside with the 1/8" angle iron in place.
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Next, I had to add bracing for the Hawse Fairlead backing plate. This plate is made of a separate piece of 3"x1/4" channel, I used this so I could match the angle of the bumper cover and eliminate stress on the cover. I then added more 1"x1/8" angle to the top extending to the 1/4" uprights on either side clearancing for the winch motor.
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You can see where I also had to notch the angle for the base of the winch.
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TBC in next post..
 
After final welding, time for some primer.
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I then painted with some industrial satin black paint I was able to get at the local Big-R and re test fit to the GX. With the upper supports installed, I realized that it would be necessary to remove the upper cross bracket and support in order to install the winch. This takes about 10 minutes and is not a big deal.
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A shot of the winch mounted and upper cross bracket re installed. I added some weather stripping to the fairlead backing plate to buffer the bumper cover. I then added 3 -3/8" washers between the backing plate and the fairlead so I am not crushing the bumper cover.
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Here is a shot of the finished fairlead installed. It is SOLID back to the frame of the GX.
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Thanks for looking, Phat
 
Great job! And great pics of it all!! :)

Just be sure to add some kind of frame bracing to bolt the assembly to the hole in the frame behind the stock bolt location. Those stock frame mounts will tear out pretty easily with a hard pull.
 
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Thank you for taking the time to do this write-up. I just purchased my winch and rope and should start my hidden winch very soon. Thanks for your help.
 
wingysataday said:
That's impressive! Great fan skills!
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BlackCat said:
Sick!
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Thanks guys!

madtoy said:
Great job! And great pics of it all!! :)

Just be sure to add some kind of frame bracing to bolt the assembly to the hole in the frame behind the stock bolt location. Those stock frame mounts will tear out pretty easily with a hard pull.
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Thank you!
I installed a hidden winch on our 08 FJ Cruiser in a similar manner and never had issue with the bumper mount pulling away from the frame mount. It is a very stout assembly with full factory welds around the base of the mount. Have you experienced this mounting plate failing? I would sure like to hear back from anyone that has experienced with this being a point of failure. Thank you for the input, I appreciate any and all feedback!!

TahoeLX450 said:
Will the air bag still deploy with a winch in conjunction with the stock bumper?
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I would say that anything we do to the stock configuration of these vehicles will affect their designed performance to some degree. Including but not limited to hanging winches and any aftermarket bumper assemblies off the front. The air bag deployment sensors are not disturbed in any way when modifying this bumper. However, the crush points on the frame extensions are virtually eliminated as the 1/4" plate is now welded to these extensions. This will certainly transmit more shock into the frame of the vehicle if there were a front impact. Not knowing exactly how the deployment sensors are designed, this may or may not affect them to a great deal. I am sure that the air bags will still deploy, I just don't know if it is easier or harder for them to do so.. Again, if anyone has experience with air bags deploying with a modified bumper, I would appreciate the feedback..

All the best, Phat
 
the frame mounting plates are simply too thin. We designed brackets that sandwich the oem frame plate and tie into the lower radiator support. Without them you will experience fatigue on the 1/8" oem frame mounts.
 
PhatFJ said:
Thank you!
I installed a hidden winch on our 08 FJ Cruiser in a similar manner and never had issue with the bumper mount pulling away from the frame mount. It is a very stout assembly with full factory welds around the base of the mount. Have you experienced this mounting plate failing? I would sure like to hear back from anyone that has experienced with this being a point of failure. Thank you for the input, I appreciate any and all feedback!!
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Yep. I had a Tacoma previously, which has nearly identical bumper mounting. Several guys pulled the mounting brackets right off the seam on the back edge where it connects to the frame. I'll see if I can find the pics. Generally, it's not an issue unless you are doing a very hard pull - but that could be any time.
 
SouthernSS said:
the frame mounting plates are simply too thin. We designed brackets that sandwich the oem frame plate and tie into the lower radiator support. Without them you will experience fatigue on the 1/8" oem frame mounts.
Click to expand...

madtoy said:
Yep. I had a Tacoma previously, which has nearly identical bumper mounting. Several guys pulled the mounting brackets right off the seam on the back edge where it connects to the frame. I'll see if I can find the pics. Generally, it's not an issue unless you are doing a very hard pull - but that could be any time.
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Great info guys! I will be sure to reinforce this mounting area. Thanks for the feedback!!


blakewhisenant said:
Thank you for taking the time to do this write-up. I just purchased my winch and rope and should start my hidden winch very soon. Thanks for your help.
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Good luck, I hope your winch fits as well as this one did!! I will update this thread when and how I add reinforcement to the frame attachment.
 
SouthernSS said:
the frame mounting plates are simply too thin. We designed brackets that sandwich the oem frame plate and tie into the lower radiator support. Without them you will experience fatigue on the 1/8" oem frame mounts.
Click to expand...

Do you guys sell the frame plates separately?
 
SouthernSS said:
the frame mounting plates are simply too thin. We designed brackets that sandwich the oem frame plate and tie into the lower radiator support. Without them you will experience fatigue on the 1/8" oem frame mounts.
Click to expand...

Hey SS - Should he cut off the original mounts and copy them out of 1/4"?
 
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