Winch Mount Design - Dimensional Data Requested

[SeventhDurandal]

I am working on designing an OEM-style hidden winch mount for the 100 series. The plan is for the fairlead to sit just beneath the existing front license plate mounts. There are some quality options out there for hidden winch mounts, but I don't like how low they sit and I also don't like that a lot of them completely eliminate the crash bar.

My plan is to fab one up at work, test it extensively, and then see how many MUD members would be interested in a short production run.

The green is the 100 frame/ radiator area.

Some of the features of this mount would be the superior strength, feet forward winch mounting, and integrated mounting point for a Bluesea cutoff switch. I will space everything for a roller fairlead so you can use steel cable, but I think I personally will be using synthetic.

Items for consideration:

1. Should I expand the sides to replace the entire existing crash bar? This would provide a bolt-on, no cut solution, but most likely increase cost.
2. As it sits, made from 1/4" steel, this weldment weighs 34.5 lbs. The entire OEM winch mount/crash bar weighs 42 lbs. What is the appetite for aluminum? Cost will be higher for sure.
3. The stand-in winch was drawn from dimensional data for a Warn 103252, a 10k winch. This is about as big a winch as I could fit. Is that enough? What are you guys running for winches?

What I am requesting from the community:

1. If you have your bumper/crash bar off, take some measurements of the frame horns and the locations of bolt holes. Because of my living situation I can't run out and take mine off right now, hoping to be able to do it this winter. I did crawl underneath and get enough to put together the green model you see above.
2. If you have access to a 3D scanner, scan the front end. To put together a comprehensive model, I would need the following scans:
   1. Front end fully assembled
   2. front end bumper cover off
   3. Front end crash bar off
   4. Inside of bumper cover while disassembled
3. Hardware knowledge. If you know what size bolts and quantities are used for the existing crash bar it would be helpful.

Thanks all, happy wheeling!

 

[cruiserpilot]

I've got a 2nd Gen Tundra so sort of familiar with your front layout. Some personal points, opinion only.
1.most winches I believe are feet down, bolt patterns are a standard. Try to stick to ongoing standard as much as possible.
2.fairlead holes are same pattern also, stay with that. Synthetic is a standard now, IMHO.
Steel wire rope is definitely on it's end game. Plan a standard Hawse style let people know and plan accordingly,
3.its going to be up to you to figure on which winches are your target audience,
but yes keeping it in the 8-10K capacity seems smart.
4.dimensionally these companies keep the external winch bodies generally consistent as well
because they are all faced with your dilemma.
5.free spool access - number one complaint I've read about custom front winch housings
6.contactor and controller access, plan for non-wireless access as batteries fail.
7.aluminum is nice, not a viable option for strength when tied in to frame etc

PS I have recently purchased a CoastalOffroad front bumper for my 2010 Tundra. It uses a central winch
mount area. The rest is just dressing.

 

[FortKnox98]

Looks like a nice design! I run a 12k winch (Badland Apex) in a hidden mount on my 100. Personally, I wouldn't want to use anything lighter-duty than that based on the weight of the rig, and I think a lot of my circle of 100 series wheelers feel similarly. It might be nice to make it accommodate a 12k...if possible.

 

[MechE30]

I think anyone with a 3D scanner also has a business selling fabbed parts. You’re likely on your own with that one.

 

[SeventhDurandal]

I've got a 2nd Gen Tundra so sort of familiar with your front layout. Some personal points, opinion only.
1.most winches I believe are feet down, bolt patterns are a standard. Try to stick to ongoing standard as much as possible.
2.fairlead holes are same pattern also, stay with that. Synthetic is a standard now, IMHO.
Steel wire rope is definitely on it's end game. Plan a standard Hawse style let people know and plan accordingly,
3.its going to be up to you to figure on which winches are your target audience,
but yes keeping it in the 8-10K capacity seems smart.
4.dimensionally these companies keep the external winch bodies generally consistent as well
because they are all faced with your dilemma.
5.free spool access - number one complaint I've read about custom front winch housings
6.contactor and controller access, plan for non-wireless access as batteries fail.
7.aluminum is nice, not a viable option for strength when tied in to frame etc

PS I have recently purchased a CoastalOffroad front bumper for my 2010 Tundra. It uses a central winch
mount area. The rest is just dressing.

1. Yes, I am using the standard bolt pattern. Feet forward simplifies the design and makes it stronger.
2. Same here, I am using the standard fairlead bolt pattern. Spacing will be tight on the bumper cover, so I might be stuck with Hawse style.
3. I think that 10k is about right for the 'hidden' audience, weekend warriors like me. Anything bigger is going to need a bumper upgrade.
4. Good to know, hopefully this will be more universal than I thought.
5. I'll have to add another picture, but I plan on clocking the clutch lever to be on the bottom of the winch. When you need to use it, you reach under the bumper and turn on the contactor, then unlock the winch.
6. I am going to find a good spot to hide the connector that will be accessible without opening the hood.
7. Thanks.

 

[SeventhDurandal]

Looks like a nice design! Personally, I run a 12k winch (Badland Apex) in a hidden mount on my 100. Personally, I wouldn't want to use anything lighter-duty than that based on the weight of the rig, and I think a lot of my circle of 100 series wheelers feel similarly. It might be nice to make it accommodate a 12k...if possible.

I'll investigate the published dimensions for the Badland. Regardless of brand, this winch mount will require remote mounting the relay housing.

 

[SeventhDurandal]

I think anyone with a 3D scanner also has a business selling fabbed parts. You’re likely on your own with that one.

Doesn't hurt to ask.

 

[cruiserpilot]

I've just learned about sendcutsend

SendCutSend: Custom Sheet Metal Fabrication

Online sheet metal fabrication service. Get custom parts delivered in just a few days—upload STEP or DXF files for instant pricing!

sendcutsend.com

These guys might help with initial design and precision needed.

 

[SeventhDurandal]

I've just learned about sendcutsend

SendCutSend: Custom Sheet Metal Fabrication

Online sheet metal fabrication service. Get custom parts delivered in just a few days—upload STEP or DXF files for instant pricing!

sendcutsend.com

These guys might help with initial design and precision needed.

I appreciate the thought, but I'm a mechanical engineer working at machine shop with a full welding and fabrication department. I can make this happen haha.

 

[cruiserpilot]

I appreciate the thought, but I'm a mechanical engineer working at machine shop with a full welding and fabrication department. I can make this happen haha.

So may times it a guy with a set of crayons and a dream.

 

[GTV]

Very interested to see what you come up with here.

 

[hoser]

Cool project but your design is substantially more complex in order to have a forward mounting winch. I have yet to see a 10k feet down winch destroy itself but I'm sure it's possible. In the end, I'm afraid it will cost as much as a full bumper (mass produced type).

 

[DuckLN]

I just want a cradle and mount for an 8274…