Initial Proposed mount system for the
Warn 15K and 12K

see our test fitting results

Click on the pictures for a blown up view
Back side of bumper with mounted 12K Warn
 Front, fairlead extenders and light mounts removed so that fairlead mounts flat against the box.
Following these instructions should give you a prototype model for a new mounting system. (For Model Use Only) We do not intend to use this box in this form.

We will want to present this new system as a one peice unit that incorporates mounts and winch box as one.

Here's how we did it...

Cut away the following sections from;

Winch Box

  • back lip of the pan
  • top lip on the front
  • all light and fairlead mounts from the front
  • front wings from the winch box, so that the front of the box is almost flat. (Leaving 10 mm is acceptable)
  • Cut out 2 horizontal sections 70 long x 30 high from the lower corners of the front face of the winch box. (30 mm from the bottom and continue around to the side for another 30 mm) This will allow for the extrusion joint when the box is pushed forward. ( pictures)

Aluminium

  • remove a section from the top surface to allow for clutch operation. (picture)

ADDED;

  • ~70 mm flat steel to height of the front
  • 3 mm plate to pan (300 wide x 210) under foot print of winch body. (picture)
  • Drill top two mount holes in front plate (winch mounts feet forward)
  • Drill two holes in pan to match with bottom holes in winch. (about 6mm aft of center on existing hole.)

FINAL CONSTRUCTION;

  • Place one bolt in the lower forward hole on the bullbar mount, to the lower aft hole in the winch box. (see picture) This will move the winch box forward so that the front face of the winch box is almost in line with the front edge of the bullbar mounting bracket.
  • Square off the top edges of the mounts to the top edge of the winch box, clamp in place and torque bolts to hold firm.
  • Weld the mounts to the winch box.

You should now be able to mount the winch for test fitting.
Reference photos - click on images for enlargements
Winch box cutout sections are 70 mm wide (along the front face) by 30 high by 30 deep (along the side). Measure a horizontal line 30 mm up from inside base of pan.
Top cut out for the clutch controls on opposite end.

(~ 110 x 65)
The strait line measure, along the back side of the site window for the drum, shown here is about 56 mm
(outside to outside edges of cutouts)
3mm plate is needed as a shim to raise the winch up to line with the fairlead holes. After removing the fairlead extensions, the bolts for the fairlead will bolt into the lower front winch holes.
From mount looking up at the bottom of the winch box you can see the lower, forward bolt hole is bolted through the aft hole in the side of the winch box. The front "wings" of the winch box must be removed before mounting to the aluminium.