Date: Tue, 13 Apr 2004 12:39:45 -0600 From: Brad Taylor Subject: [DTLC] ARB install with a pto winch To: list@rmlca.ab.ca, dtlc@helios.net, landcruisers@birfield.com Reply-To: dtlc@helios.net Well I finally got my ARB bumper for my HJ61 and we installed it with the factory pto winch on the weekend. A little fabbing and cutting was required and it moved the winch about 1/4 closer to the truck. This is what I did. I got the ARB that fits the low profile warn winches. I am super close to the factory position and no driveline lengths where modified. I used the factory roller fairlead (with the bottom ears cut off) but discarded the support hoops that go from the top of the fairlead to the rear of the winch. I also removed the factory shims. To start with I cut off all the protruding items on the mounting face plate on the front side of the bumper. I also cut straight across the top of the middle hole on the face and removed the tack welds from the lower tube. This gave me a clean flat surface for mounting the fairlead and winch to. I then tried to drop the winch with the factory angle iron attached into the backside of the bumper. The angle iron is to long and each end has to be shortened. Once this is done you will notice that the lower rear tube cross member must be cut to allow the piece of angle to sit flush on the rear mounting bracket. Position the winch side to side (this should be easy if you cut the same amount off each end of the angle iron) and then mark and cut this tube to allow enough room for the winch to sit flat. With this done I snugged the winch up to the front of the bumper and scribed the paint to mark for a mounting hole. At this time you may notice that the rear holes in the angle iron don't quite match up to the mounting brackets on the bumper. Don't worry we will deal with this later... Once I had one hole drilled, I elongated it up and down (maybe 3/4") and attached my fairlead, through the bumper, to the winch. I then positioned the fairlead (and attached winch) as high as I could so that I could tack the top of the fairlead to the bottom of the tube that I had removed the original ARB metal from. I then snugged up the bolt, check for level and clearances and marked my other three holes using the fairlead as a template. You also need to remove a bit more metal from the plate (of the ARB) to allow for proper use of the fairlead and spooling of your cable because of the winch offset. With this done I reattached the winch and fairlead. The winch, sitting in the ARB is now about 1/4" closer to the truck then factory. As mentioned above the mounting holes on the angle iron do not match up. To remedy this I cut a slot about 5" in from the edge one side of the angle iron (I think that would be the horizontal side) and bent the piece to fit the holes. I then welded the slot shut. I originally thought you could just open up the holes on the angle but you can not get the other set of mounting bolts in due to clearance issues with the angle iron. This leaves the lower rear tube cross member that we cut earlier. You need to have access to the shear pin on the winch so a U shaped replacement piece out of flat bar sides and the cut out piece of tube was made. I am not sure that you really need much strength here with the addition of the factory angle iron, but you are better safe then sorry. Then mount the bracket for free spooling and engagement and your done. And that's it. I sprayed some paint on the grinding and new welds and greased up the splines and attached the whole unit to the truck. It works great and looks good. I have a couple poor pics I can email if you want to see it on the truck. bt Date: Thu, 15 Apr 2004 07:53:32 -0700 From: Dave Tay To: dtlc@helios.net Subject: Re: [DTLC] ARB install with a pto winch Reply-To: dtlc@helios.net Brad Taylor wrote: >I have a couple poor pics I can email if you want to see it on the >truck. > >bt Brad, would you please e-mail me the pics? So the tube crossmember on the ARB had to be replaced with one with a curve in it to clear the winch? What made you decide to use the front stock plate instead of bolting the winch directly to the bumper? I am planning to bolt my winch directly to the bumper so it replaces the factory front plate. Dave Date: Thu, 15 Apr 2004 09:21:24 -0600 From: Brad Taylor Subject: Re: [DTLC] ARB install with a pto winch To: dtlc@helios.net Reply-To: dtlc@helios.net > On Behalf Of Dave Tay > > Brad, would you please e-mail me the pics? So the tube crossmember on > the ARB had to be replaced with one with a curve in it to clear the > winch? What made you decide to use the front stock plate instead of > bolting the winch directly to the bumper? I am planning to bolt my > winch directly to the bumper so it replaces the factory front plate. > > Dave Yes, the tube on the lower backside of the ARB was cut and modified to clear the input shaft of the PTO. I didn't use the stock 'cruiser front plate only the fairlead. The winch is bolted to the bumper as well. None of the stock holes for the cable came close for the position of pto drum. Also, because of the pto design and it needing to spool in on the topside of the drum, I thought it would be easier to just cut all of the protruding crap off of the ARB and start with a clean, flat mounting plate. It worked out perfect because the stock fairlead uses its bottom holes, through the bumper and the top of the fairlead reaches the bottom side of the front tube to be welded for extra strength. Clear as mud? :-) bt