[jyobeb]

The material used for the running boards are 3/4" Transport grade, waterproof, compressed plywood. I know they look awful. Will be sandpapering it down and changing it to some other finish.

[jyobeb]

The almost finished rear bumper with cutouts for the jacking point.

[jyobeb]

My front bumper with the concealed winch.

[svsantosh]

Originally Posted by jyobeb

My front bumper with the concealed winch.

How will you access the clutch and ensure correct re-spooling after using the winch?

[Edmund]

OT:

In case anyone here is looking for a Willys station Wagon, on a recent trip to Pune I spotted one in good nick on the Pune-Solapur Toll highway!

Just Saying!

[jyobeb]

For you Santosh. As for the spooling I will have to be extra careful.
I don't want to have an openable cover and hence am going with this.

[gthang]

Originally Posted by jyobeb

For you Santosh. As for the spooling I will have to be extra careful.
I don't want to have an openable cover and hence am going with this.

Hi Jyobeb,

Dont know if you have access to a crimping place, if you do, I would suggest sacrificing a layer or two of winch cable. You lose some total distance, but getting in a bind due to bad wrapping would be less.

Cheers.

[jyobeb]

I am actually giving serious consideration to plasma rope. I have already bought the rope along with the fairlead.

[jyobeb]

After giving serious consideration to your doubts, I have decided to make an opening on top to help guide the cable.
Thank you for your concerns.

[Tejas@perioimpl]

Dear jyobeb, Consider fabrication of a winch cable tensioner. Very simple to fabricate. Will take care of the bird nesting of the cable whilst free spooling and re spooling. Don't have access to my comp now to post pics. Will do so on Monday. (Accessing via mobile app now).

[jyobeb]

Modified. Adjustment and viewing possible now.
@ Tejas, would really appreciate pics. Thanks man.

[Tejas@perioimpl]

Originally Posted by jyobeb

@ Tejas, would really appreciate pics. Thanks man.

Got access especially for you.

Here you go:





Googling will give you more options as well.

I plan to get this made as well but will probably take some time before i get to it.

Vid:

http://www.youtube.com/watch?v=dI3mGs2Y2mQ

Links:

http://towtalk.net/forum/topic/How-d...oner-work-.htm

http://www.winchbin.com/1286/how-doe...ensioner-work/


Also, if you plan to use the winch on sustained pulls you will need vents to aid in cooling.

EDIT:

Try to source a metal hawse fairlead for your rig. It will look much better than roller. (The aluminium one for plasma rope won't do).

EDIT2:

Another Suggestion: Because you can't see your drum clearly, just mark the cable when 6-7 turns are left on the last wrap of the cable on the drum. You can spray paint or put a heat resistant sleeve so you don't spool out any more rope otherwise, you will loose the grip on the drum. Minimum 6-7 wraps are necessary.

[jyobeb]

I decided to louvre my bonnet rather than add a intercooler scoop. Also fitted rear seat belts.
Next, the winch cable tensioner.

[svsantosh]

I see a monster audio setup coming up?

[jyobeb]

Originally Posted by svsantosh

I see a monster audio setup coming up?

Nothing like enjoying good music on the move, and to drown out all the other rattles!
A ZAPCO 4 channel and a JBL Crown BPX 2200.1