Outer Limits 4x4 Board

My Champion C 8000G 12V winch turned up, and I have started fitting it.
I'll update the thread as I do more work.

Paul.

The winch:

The fairlead and hand controler and safety hook.

Trick, keyring size winch remote and control box.

I did my usual bit of 'about there' bit of measuring and got the grinder out.
I cut out the front lower body member to sit the winch as far back as possible. I will replace this woth some fabbed up tube.

More pics. Positioned as far back as possible.

Lets hear it for Donkey Saws!

And some more of the cradle. I know the steel is a bit overkill, but I've had it sitting round the workshop for over 10 years and I felt it needed a new home.

This is how it will sit in the cradle. I want to mount the two recovery points on either side of the cradle. The cradle will then bolt on to the chassis.......I hope.

nice work mate!

Keep us posted

Nice fab work mate

Looks good so far. I have a similar unit already mounted behind my front bar and it works well. Have bolted to the chassis rather than welded and whilst the brackets were a wierd shap it all came together. There's some pics on WARFS.ORG of the fit if your interested.

Moved and redesigned the controls up into the engine bay and fitted a MUCH larger battery. Once again see WARFS.ORG

Thanks for the nice comments.

I had a look at Warfs , and the winch install looks really good.

I didn't get much done this evening as I am full of Flu and feel terrible.
I finnished welding the cradle and cut trim that sits under the headlamps.
I cut the swaybar mounts off to allow me to fit a bigger plate to the front chassis legs.
Oh yeah, and I fitted an extra horn as my car only had one but was wired for two???

Paul.

A few more pics:

Last two photos for this evenings work. If all goes well I should have it all fabbed up and painted over the weekend and if I have time I will mount the solenoid pack under the bonnet.. Just the twin battery and split charge to sort out then.

No chance of re-fitting the sway-bar now!!

I've dragged myself out of my sickbed and got a little more done last night.

The plate that will weld to the chassis is made( actually welded on now, but no pics yet) , and the winch cradle will bolt to this. I will hace to cut the tube bumper to fit round the winch, but as the cradle is removable, I will weld the bumper to it to make it really stong.

Paul.

More pics:

A couple more:

Very impressive work.

How much extra weight do you reckon all that will add!? Could be time for upgraded torsion bars?

You're right, I think its time to put my hand in my pocket and buy some uprated torsion bars.
With all the steelwork and the winch in place it drops the front suspension half an inch. One and a quater turns on the adjusters sorted this, but I have still got to fit a second battery, ground anchor, dive bottle for an air supply, and all my other recovery gear! By the time I've added a passenger I'll probably be back to standard ride height!!

Any reccomendations on torsion bars then? I think my options in the UK will be limited though. Does anyone know if the front bars from a UK Fourtrak Independant would fit? They run a wider track and are a heavier car so in theory the bars should be uprated in comparison to the narrow-track Sportrak?

Paul.

You might want to look at Fox airshox. I have been running them for almost a year now with NO springs at all on the front. I have an all 3/16" steel bumper and a Warn 9000 winch. No problems changing ride height or spring rate and they are completely rebuildable. Very soft ride and they make clearance for the 35's.

Another option would be to keep your stock torsion bars and add HiJackers.

Are the chassis on Feroza's heat treated like many trucks ? If so welding to them is an issue as it causes weakening. I have no idea wether Daihatsu did this - but am just raising it as a possible word of warning.

My gut feeling is its probably OK but...........

everything on the chassis is welded on from factory...... toyota have those rivet bolt lookin things, welding onto a toyota chassis doesnt look as neat (buldges more on metal than chassis) as say a suzuki chassis and the rocky chassis looks the same.

Thanks everyone for the helpful replies.

Fox air shocks are out of the question as they are worth more than my car!!
The winch bumper and winch weigh in total 10 stone! I will wind the torsion bars up a little more and see how irt behaves. I might try replacing the front shocks with a set of cheap coilovers with some light weight springs in them.

The winch bumper is now painted and ready for fitting. I am out for a play weekend on friday, so I need to get the winch wired in by then. I still need to make the second battery mount and fit the split charge relay.
Enjoy the pics.

Mac.

Two more.

All bolted up now.

Hope you all like the finnished article.

Paul.

looks tuff.
you seem to be going hard on modifying your car atm. Having a pit definatly helps.
I miss my pit.

Tuff looking roza eh? i'd be scared to park next to ya... Just kidding

My modding to this car is almost done. I use it day to day as well as for playing, so I've limited how far i will modify it.

Once this one is finnished, I can start on my other Sportrak. It's having a Rover 3.5 V8 with autobox, 4 link Toyota Axles, difflocks (switches for the ditches ), front and rear winches, pick-up or tray back(not decided yet), and 36 inch tyres. The Rover box and Toyota axle ratios match to retain standard gearing with 36 inch tyres. It will have external rollcage and all the usual additions to make it better in the mud.

I cannot wait to get cracking on it. I have most of the parts, I just need the get my trusty grinder out again.

Mac.