Warn winch rebuild, CCOT bumper, etc.

[emac]

I picked up a 8274 from CL this weekend. I have been searching for one for a while, and found one close by that I just couldn't pass up. It came off of a 75 Heep. My first experience with a quality winch. It was in working condition. Dang it's heavy.

I just couldn't leave well enough alone and decided to tear it down, learn how it works, replace the worn stuff, and clean it up. Glad I opened it up, as it had a fair amount of water in it. I ordered a new lower seal kit and brake service kit. It should turn out nice. Many thanks to the forum for some great threads on the 8274. I wish someone reproduced the Warn ID plate decal!

As my build sits idle at the body shop, I have been changing my mind on a few things. Originally, I really liked the stock look of the front bumper, and thought the aftermarket short ones looked silly. Now, with the winch, I am starting to warm up to the short bumper. I am looking at the CCOT 8274 ready bumper in silver. Of course, I have a brand new OE bumper in a box, and a spare used one. Has anyone installed one of the CCOT bumpers? Any comments on it? Looks like a quality product. i have also looked at the JTO bumper. It is longer, but comes only in black. I guess I could paint another bumper!

I considered trying to reinforce my used bumper and build a mount for the winch. I want the winch mounted behind, rather than on top of the bumper (for radiator air flow). i am installing A/C. I didnt see any detailed designs that I thought I could replicate. I want the cable coming through the bumper. If anyone has built a mount and retained the stock bumper, I would love to see a picture or two.

Here are a couple of pictures of the winch:

 

[spotcruiser]

Yep, clean that winch out, give it new seals, give it new oil, and it'll be good to go. Use a little RTV around the mating surfaces of the top and bottom gear cases and between the clutch knob plate and upper housing..

 

[ginmtb]

Check out @Kayaker 's solution in this thread:

Winch question

I also posted a photo of my bumper which was a dealer option - it has the same mounting style.

 

[ginmtb]

Here's a photo of his modified OEM bumper:

 

[gcrump01]

I also welded a winch plate to an OEM bumper. several pics in my build thread

 

[Jdc1]

Forum sponsors Trail Taylor and 4plus both have awesome aftermarket winch bumpers.

 

[eman375]

Forum sponsors Trail Taylor and 4plus both have awesome aftermarket winch bumpers.

X2 for Jason at Trail Tailor. A rock solid , high quality product and working with Jason is a pleasurable experience.

 

[emac]

Dang, you guys are awesome! Good ideas. I was really worried about posting, because I thought this was a topic that had been beaten to death. I searched a lot of threads and dont recall seeing Kayaker's picture or that thread. I am a bit worried the strength of the OE bumper so I may see if I can add some hidden reinforcement. I have a plasma torch and a welder that needs to get some use.

More things to think about, glad I didn't jump the gun and order a new bumper. I think I am going to play around with fabbing up something to go with the stock bumper. Just seems to fit my stock style build.

 

[78fj40mg]

Here's my CCOT bumper with a Warn winch

 

[emac]

Mike, that looks nice! I didn't realize CCOT had bumpers that long. I like that better than the ones that go just past the frame rails.

More cleaning and polishing. Trust me they looked way worse when I started:

 

[78fj40mg]

Mike, that looks nice! I didn't realize CCOT had bumpers that long. I like that better than the ones that go just past the frame rails.

More cleaning and polishing. Trust me they looked way worse when I started:
View attachment 1275295

Hey Ernest, looking good!

 

[thebigredrocker]

Here's a battering ram made by @4x4labs. It's made so an 8274 will bolt right up. I'll soon have my 8274 mounted. I believe Luke makes them without the tapered ends if you prefer the straight look. This is an option for peeps who want a super beefy bumper.

Install was easy. Position bumper with mounting plates. Tack mounting plates to frame rails. Unbolt bumper from mouting plates and finish the welds.

 

[Michael Brady]

I got the CCOT shackled bumper w/o winch option. Pro's - its 3/8" steel, very stout. Con's - the shackle mount holes are way over sized for the shackles and the paint finish is crap! They say it is powder coated, if it is, its very low quality. I have rust spots here and there and it scratches off if you look at it wrong. I am planning to repaint mine at some point.

 

[emac]

Thanks for the insight, Michael. I have had hit or miss with CCOT quality during my build. Some stuff is great and other stuff terrible.

 

[Michael Brady]

Thanks for the insight, Michael. I have had hit or miss with CCOT quality during my build. Some stuff is great and other stuff terrible.

That has been my experience as well.

The build quality of the bumper, hole placement, etc is excellent. I am not sure why the holes for the shackles are oversized - maybe that is common? In my mind its distributes the weight and load better if the shackle fits more snug. For under $200 with shackles though, I just didn't see it being worth my time to try and build something similar myself. My plan is to buy bigger shackles for better fit and repaint with Epoxy Appliance Paint which Ihave found to be a good all purpose finish.

 

[Kayaker]

I am a bit worried the strength of the OE bumper so I may see if I can add some hidden reinforcement.

It's not apparent from the photo of the winch mount on my FJ40 from the above photo, but it's a 3/8" thick steel plate welded, both top and bottom, to the back of the stock bumper and spans the entire distance between the frame members. I've used my winch quite a bit over the past 40 years and the mount and bumper have given no signs of strain. It would be pretty easy to add additional reinforcing below the winch connecting to the frame members on both sides without losing the stock bumper; probably only cost another 2 mpg with all that extra weight up there I really like the look of that stock bumper and just couldn't find a replacement that I liked as well so this worked for me.

 

[emac]

It's not apparent from the photo of the winch mount on my FJ40 from the above photo, but it's a 3/8" thick steel plate welded, both top and bottom, to the back of the stock bumper and spans the entire distance between the frame members. I've used my winch quite a bit over the past 40 years and the mount and bumper have given no signs of strain. It would be pretty easy to add additional reinforcing below the winch connecting to the frame members on both sides without losing the stock bumper; probably only cost another 2 mpg with all that extra weight up there I really like the look of that stock bumper and just couldn't find a replacement that I liked as well so this worked for me.

Thanks for the information Kayaker. I have plenty to keep me busy for the time being before I get to the winch. I have a spare OE bumper, I may play around with and try to duplicate something like you have. Any chance you have a picture of what it looks like on the back side of the bumper? Just to give me an idea of the design. I like the stock bumper look also.