winch bumper project

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Here are some pics of the winch bumper I recently built for my pick-up.  These are of the design process.  I built it from 1/4" plate.  I will post more pics of it finished on  Friday.  I made the complete bumper out of cardboard before I cut the steel.Thanks,Geoff Attached ImagesThanks, Geoff
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Reply:Looks good to me.  When I built mine I had to install extra springing in the front end to keep the nose of the truck off the ground though.Are you planning on a fairlead in front of the bumper?Will the side areas have a bottom panel so you can store chains and shackles in them?Appreciation Gains You Recognition-
Reply:Franz,The bumper is complete now, but I don't have pictures yet.  I didn't think of the storage idea thats a good one.  Too late now though, I had it powder coated.I did have to have the torsion bars adjusted to level it out.  It does have a roller fairlead for the 12,000 lb hydraulic Mile-marker winch.  Thanks for the reply,GeoffThanks, Geoff
Reply:Does that winch hook into the power steering pump hydraulics?Appreciation Gains You Recognition-
Reply:Franz,  Yes it is plumbed into the power steering circuit.  It works great, it will pull all day long.  It is a 2-speed unit.  High speed for line retrieval and low for pulling.  Very impressive package.Thanks, GeoffThanks, Geoff
Reply:Did you install an oil cooler to keep the system from overheating?How did cost stack up against a similar size electric winch?Appreciation Gains You Recognition-
Reply:I remember looking at Mile-Marker hydraulic winches a few years ago.  I was impressed with the innovation, but didn't really see a need for me to deviate from the occasionally used Ramsey electric.  Also, I think I remember that you don't have power steering while using the winch and for off-roading, sometimes you just might be doing both, though not to be considered for the work truck really.  I'd be interested in your opinions on the installation as well as total package costs.
Reply:Looks good to me, but if I may suggest, I think bumpers look better if they sit flush with the body, meaning remove those plastic fillers under the grille.  I plan on narrowing my stock bumper and modifying the bumper brackets so it sits flush with the body and is pushed back under the grille.  Then when I get around to making my tube bumper for my 4x4 one, I plan on eliminating those fillers.Also are you planning on incorporating tow hooks at all?
Reply:Franz,I did not install a oil cooler, they claim it will actually lower the fluid temperature having the winch in the circuit.  I guess time will tell on that one.  Price wise, it costs less than the electric I would have bought ( Warn 8274-50= about $ 980)  I got this for around $865 including install kit.  The Warn is rated for 8000 lbs,  but I have seen it do much more than the higher rated capacity winches.  It uses the same mounting pattern which is handy.MAC702,About the steering while using the winch, you can steer, but I think the power assist is not as strong.  It is plumbed in series, so fluid goes to steering box no matter what you're doing with the winch.  Installation was very straightforward,  common sense needed though.  Instruction manual leaves some to be desired.  All fasteners are stainless and the hoses and fittings are very well made.  Antibling,I did weld on some D-ring shackle mounts to the bumper.  Got to stick weld with the T/A 185  with some 6010 and 7018.  Very nice arc!PS:  I will wash the bugs off and take some pictures tomorrow.Thanks, Geoff
Reply:Here are the pics of the bumper completed. Attached ImagesThanks, Geoff
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Reply:Finally,Me and the finished product. Attached ImagesThanks, Geoff
Reply:You ain't finished yet.Coil the cable up in a 5 gallon bucket, and let it sit there covered with used motoroil for at least 24 hours.  Where you let the oil drip after spooling the cable back on the winch is up to you, but if you don't oil the cable you'll replace it in half the amount of time.Also, throw a blanket in the cab behind the seat.  Hang the blanket over the cable during long pulling operations, so just in case the cable breaks, it doesn't whip back and remove your head.  The blanket can also be helpful if the winch didn't pull you out, and you need to spend the night in the cab.Appreciation Gains You Recognition-
Reply:Franz do you know what that does to the cable to make it last longer?
Reply:Well Dman, I ain't Franz but when the cable uncoils and comes under stress the strands will be shifting and rubbing against each other and even individual wires within the strands will be moving against each other so the lubrication will greatly reduce abrasion and cutting.
Reply:And btw, good looking job, G.
Reply:Soaking a cable full of oil helps prevent water from soaking in and rusting the individual strands, as well as helping to lubricate the cable as it works.The blanket trick doesn't make the cable one bit stronger, but when the cable breaks, Notice, I didn't say IF, the blanket becomes a brake to the flying cable in the same manner as a parachute.Appreciation Gains You Recognition-Great looking bumper, I really like the bevel on the bottom. It finishes it off nicely!Luc
Reply:Franz,  I read about the blanket/jacket issue a long time ago, and can say from experience that it works very well.  I was winching out some shrubs for my grandmother a couple of years ago when the chain I was using, not the cable, broke.   Everybody gets disgusted with me when I take the extra time to apply the blanket, but I know better than to try to hurry up things while winching.  I had not heard about the oil soaking though,  I may try to do that if I get ambitious enough to fight the 3/8"x100ft cable this weekend. Thanks for the advice. Thanks for the replies, GeoffThanks, Geoff
Reply:if you dont feel like dealing with the wire winch line. I start looking into this http://www.rockstomper.com/catalog/recovery/ropes.htmhave you hugged your miller today ?
Reply:Franz is right, the blanket saves lives, there have been far too many people up here pulling out tractors, and they get hit by the chain or cable when it comes through the back of the cab, they have been paralyzed or killed.
Reply:If you think soaking 100 feet of 3/8 is a bitch, you oughta strip 250 feet of 1/2" off a drum and stuff it in a barrel.  That's what I have on the winch on the front of my M-37 Dodge.Appreciation Gains You Recognition-
Reply:Hey Franz,We have talked on Big Electric, I have a 53 M-37, W/oW. What are your current projects for you M-37?TTYL,Bruce The Welding ChefLincoln Weld-Pack 3200 NORWELD StickStanford Hill Farm
Reply:I'm only into year #4 of converting it to power brakes so I can stop the damn thing.She's camping comfortably in the garage for now.Appreciation Gains You Recognition-
Reply:You'all got that right time spent slushing cable is a good investment. Remember if you use your winch much, a yearly reslushing, and inspection for "fish hooks, and other broken strands is time well spent. I won't use chain for any rigging if I can avoid it. I like wire, or nylon straps. Chain doesn't give a warning when it lets go.I don't have a winch for my dodge, I carry a "farm jack", a bunch of shackles, and about a 100' of nylon strap with eyes on both ends, Not hooks.
Reply:Very nicely done, got any construction pics or details, I am thinking of building a minature one for my rangerWhen in doubt weld it
Reply:Hipro, Sorry but those are the only pics I took while building it.  I would really recommend building it out of heavy cardboard first.  I just started with the winch dimensions and went from there.  If you have any questions or would like some specific pics of it, feel free to ask.Thanks, Geoff
Reply:Nice fab job Geoff.  Looks great !
Reply:VERY Nice!!  I am inspired - I just bought a new truck and  was planning on making a similar unit - Although I had no immediate plans for a winch. _ I also like the idea of a storage compartment but would not want to sacrifice the structural integrity - So I'd have to think about that. Man! that's what I love about fabrication - to go from a flat piece of metal to THAT! - Nice Job - You should be proud of it.Learn from mistakes but do not be ruled by them
Reply:nice     Mike
Reply:Very Nice.... Is the entire bumber made of 1/4" plate?  How much do you think it weighs?PackratLincoln 225 AC/DC, Hobart 140 Mig. Oxy/propane Victor torch.(2) Makita 5" angle grinders  one with zip disk, 14" chop saw.  and just about every other tool you can think of. Whoever has the most toys when he die's ..... Wins!
Reply:You did a very nice job of your bumper. And the hints about the oil and blanket are good tips. But there are special lubes to protect your cable. They are a lube and water protectant at the same time. If you plan on lots of off roading, Get a snatch block, So you can double your pull power. Tie block to tree and cable back to your truck