hilux winch bullbar. Inspiration for other builders

[old lux]

does anyone make a winch bullbar to suit a solid axle lux thats winch compatiable for a 12,500 pound winch

ARB are only rated to 9500 and i havent rang TJM or OL yet,

I also had a look at dragtec customs page and they make a winch plate but thats only 9500 pound also.

Even If Someone makes a BOLT ON WINCH MOUNT that is stong enought for 12,500 pound i'd be happy to make the rest of the bar myself like i have done.

cause i bent mine on the weekend

have a look in general tech for photos if you want

[CRUZAAMAD]

id be inclined to use 75 b 50 angle either 6mm or 8 and weld that to the plates bolting up to the chassis.
then make your bar off, and around that.
the roller fairlead would also be recessed because of the angle, and the face could be out of 3mm.

i made one up, but was in a rush to fit the winch to my cruiser, trip to frazer island..
soo just cut my bar up and made it fit.

soo 75 L
50
And run a 6mm flat bar across the bottom, to stiffen the two angle droppers up..


ill try and find the piece i made up,..... today when the sun comes up..
if youd like..

[old lux]

This is what I ended up making. Not exactly perfectly may hung but I'm happy. It's make with a 8mm baseplate with 6mm gussets and a 6mm front plate with 40nb (3.7mm wall thickness)

[DUDELUX]

So much better than anything I can do, so please dont take this the wrong way, but I have to say, quality bends and notching right there.

[brad 93hilux]

That thing must have dropped the suspension down a bit, it would be farkn heavy

I made my tube bar from cds 2.6 wall 1 3/4 (going to build Exo off it later) and made a 3mm winch plate..
But I've just cut off the 3mm cradle And am getting the same thing made from 6mm plate but even 6mm is over kill.

The angle I put on the classy that cradle is welded to has 12 high tensile bolts and is 150x 60mm x10mm thick (what was available at work) so would never come off truck..

[old lux]

Yer it's fairly heavy ill have to put it on sone scales snd find out but it also levelled the front to rear as the rear use to sit a bit low.

I used 8mm plate as everywhere I looked used 1/4" and said its only rated to 9500 so wanted to make sure I'd never have a issue with my 12,500. I used the 40nb as its hard to get the pipe you said. A fella waited 3 months for his to turn up.

[old lux]

So much better than anything I can do, so please dont take this the wrong way, but I have to say, quality bends and notching right there.

Yer best I did it a super heap bender lol. And stinger is just tacked there gotta take take it off and botch it just wanted to get a look of I liked it. The bar hasn't been fully welded yet only tacked together

[brad 93hilux]

The main reason I used that is because after buying a jd2 bender and notcher plus 6 lengths of cdw tube I was broke lol, I bought tube for roll bar/cage and just simpily used what I had.

But 8mm is super thick, did u cut air holes in bottom plate to let air in for radiator?
My Arb bar was 9500lb but it was only 3-4mm thick but it got its strength from bends and gussets which plays a big part in it, that's why I went 3mm originally to save weight, and it was strong enough for winch but wasn't to land whole weight of truck on it coming off some big tyres. Now it'll be 6mm

Do u think bottom tube sits a little low? Looks like it does in photo

[old lux]

The main reason I used that is because after buying a jd2 bender and notcher plus 6 lengths of cdw tube I was broke lol, I bought tube for roll bar/cage and just simpily used what I had.

But 8mm is super thick, did u cut air holes in bottom plate to let air in for radiator?
My Arb bar was 9500lb but it was only 3-4mm thick but it got its strength from bends and gussets which plays a big part in it, that's why I went 3mm originally to save weight, and it was strong enough for winch but wasn't to land whole weight of truck on it coming off some big tyres. Now it'll be 6mm

Do u think bottom tube sits a little low? Looks like it does in photo

I bent the crap out if my ARB bar and that's 3mm with 3mm gussets where the winch goes. And I rolled the bolt on itself

No air holes in the 8mm plate as that sits flat. I worked out no less airflow then my ARB Bar if not more now.

Yeh if I had of had a good bender it would of looks nicer but you do what u can do.

I don't feel it's 2 low things its just the angle of the photo.

[brad 93hilux]

Yeh it's hard to tell with pics, must have had a crap arb bar because my bar had hit big roos, hit trees, winched shi# loads over the years which includes stalling out winch and my bar was ok, I sold it and its now on another truck going strong..

At least you had a go yourself, better then paying a fortune

[old lux]

Yer I never had a issue other it running over things or hitting things. I dunno what happened when it failed. Because the week befor I'd done a triple line pull on a 80 series. Then all of a sudden doing this single line pull it bent my bar. So not sure.

[brad 93hilux]

A single line pull puts 3x more load on it then a triple line pull

How are you gonna finish off the pipes where all 3 meet the guard

[old lux]

How does that work? I get pulleys take off load but the load on the bar should still be the same.

I plan on leaving the bottom pipe roughly 2" longer so I can going my brush rails in there and ill proberly cap the other 2 pipes.

I picked it up today with no winch weights about 50kgs I reckon so a bit on the heavy side. But time wil tell

[brad 93hilux]

Because every pulley it goes through it halves it because the pulley then takes half the load.

Ever looked at a overhead crane/ mobile crane to see how many times the rope wraps back and forward through pulleys.
The more it is wrapped the more it can lift up until the ropes breaking strain.
Some overhead cranes can be rated to 20 ton (as a example) but the winch itself is only rated to 2T.

The way a winch on a 4by is rated is actually minimum breaking strain not the recommended load, so a 9500lb winch though it may pull 4T it is at its limit and cable is at risk of failure. So ideally u use pulley blocks (snatch blocks) because it reduces loads.

Understand, google pulleys and see what comes up.

Brad

[old lux]

i understand how pulleys work and how they share the load. but in thoery the bar is still getting the same load put threw it correct?

hence in the crane suituation u were alking about. woukdnt matter how many pulleys are on it at the end where it all slides is still the same load whether it be a bi winch or little winch with heaps of pulleys? or am i wrong somehere?

[brad 93hilux]

http://www.explainthatstuff.com/pulleys.html" onclick="window.open(this.href);return false;
Have a read and let me know how u go

[old lux]

cheers for that bud. makes sence. the way i was thinking was wrong lol

oh well the enw bar is solid and over engineered lol. should be fine for life

[brad 93hilux]

Yeh that's it, good to know anyway.

At least you won't bend it in a hurry.

[old lux]

Yer that's true. It's fully welded and complete just buying new blinkers tomorro the. Painting it with the rattle can. Satin black do its easy to touch up. I thought about powder coating but then I'd have to grind all welds smooth and make it look flash only to hit things and chip it

[brad 93hilux]

Nice, I paint my bar work with a spray can as it cops a flogging in the scrub and when I come back I just re spray it again and it looks like new.

[old lux]

Yer man painted it up. All left to do us last coat tomorro morning then mount in Monday at work and wire up blinkers. Then drop winch in. It's all aired up so will only have to do main positive and earth. Then FINALLY DONE lol

[old lux]

All mounted up





Enjoy[/quote]