My portable "winch in a box" (better than nothing) creation

Not wanting a full blown winch setup (yet) and not liking one available solution (https://www.amazon.com/Superwinch-1140232-Portable-Synthetic-D-Shackles/dp/B0166H2V0C) I decided to make my own!

Did a test pull today on a 15 degree hill and it didn't even sound loaded. Obviously that's a pretty easy test not having the additional forces of mud/rocks/whatever you are stuck in/on. Also bought an RRP (https://www.amazon.com/Factor55-Retention-Pulley-Snatch-Block/dp/B0848Q8B76) to help if needed.

This isn't a perfect solution - It takes time to set up but it does meet my "better than nothing" requirement. The jumper cables are long enough to pull from the rear as well. It's almost entirely a Harbor Freight kit. Using the HF bluetooth remote to operate.




Parts list:

Winch: https://www.harborfreight.com/5500-lb-utv-long-drum-winch-with-synthetic-rope-57535.html

Remote: https://www.harborfreight.com/wireless-winch-remote-56504.html

Jumper cables: https://www.harborfreight.com/20-ft-4-gauge-heavy-duty-jumper-cables-57602.html

Case: https://www.harborfreight.com/4800-weatherproof-protective-case-x-large-yellow-56865.html

Button head bolts for winch to plate: https://www.amazon.com/dp/B0B8SJB6XK

Copper lugs: https://www.amazon.com/dp/B0BNMPY4F3 (the winch comes with various wires that you can also cut/use some of their ends)

Bolt caps: https://www.amazon.com/dp/B093YWV6R2

Bolts for fairlead: https://www.amazon.com/dp/B0863NJ4N9

Steel plate: https://www.ebay.com/itm/195552415560 (you could make this yourself - had a friend weld on the extra tabs you see and had it powdercoated locally)

Shackles for plate: https://www.amazon.com/gp/product/B01LWMG41R


The battery lugs on the side can be whatever you want or have lying around (or use some from the button head kit above).

What are the connectors from the winch to the plate through the plastic?

Bronco1971 said:

What are the connectors from the winch to the plate through the plastic?

Click to expand...

https://www.amazon.com/dp/B0B8SJB6XK

We're not talking any quality grade 8 stuff here The ones the winch came with were even worse. I would doubt that it has enough power to shear them off.

Nice concept and execution! What are the parts and prices? I like that it’s portable and you could easily move it around to other vehicles that may be in need.

Now, go get stuck and let’s see that sucker in action!

Well 4k winch is not very good for anything in the real off-road world unless its for a ATV. Secondly those 4 small screws holding that winch in place on that plate are in my opinion useless. The torque being applied in 2 directions will most definitely sheer them in a real scenario.

But as you said, its better than nothing as long as you don't use it in real off-road scenario. A quality hitch cradle and 9k winch would be much better and is not hard mounted to vehicle and would of been in or near the same price range.

Grumpy said:

Well 4k winch is not very good for anything in the real off-road world unless its for a ATV. Secondly those 4 small screws holding that winch in place on that plate are in my opinion useless. The torque being applied in 2 directions will most definitely sheer them in a real scenario.

Click to expand...

I had the same concern, so I looked it up. Assuming these are M8-1.25 fine thread, and grade 8 or above, the proof load shear capacity is about 7000# each. Total capacity of 28K# again, assuming equal distribution of the force. Theoretically that winch should fail first. It's really weird, they look way too small. The plastic of the box being between the mounting surfaces introduces a bending load.

Though I would not stand in line with that box while winching. It's an interesting concept and I like it, but there are a lot of failure points here, and I'd want to see a lot of testing before I used it in the field.

OP, do me a favor, throw a jacket over that winch line.

They aren't quite as small as they look and are no different from what the winch comes with to mount it, just slightly longer.

If I'm thinking of it correctly, any bending type load will be negated by the box itself moving in free space.

Sharpie for reference..

n0xlf said:

If I'm thinking of it correctly, any bending type load will be negated by the box itself moving in free space.

Click to expand...

That is incorrect.

There should be a way to mount the box without having it between the load cases.

Describe what you mean...

n0xlf said:

Describe what you mean...

Click to expand...

OK, I'm just spitballing from the pictures, so you should certainly check the veracity of my recommendations.

You want the box to be in no way involved in the load bearing structure. So, cut out the area of the box the size of the mounting boss of the winch. Now the winch is directly on the plate. Now you still have an enormous area of plate that you could could simply bolt the box to. Offset the non-structural bolts so they are not in line with the structural ones. I would be to the outside of the load path with the "box only bolts."

Gotcha - I see what you are saying, but I don't see where there are forces outside of those that are directly acting perpendicular to the bolts themselves, thus transferring all of the force to the plate. Now if the box couldn't move in space (go up/down, twist, etc.) then I could see non-perpendicular forces (those that aren't parallel to the winch/plate might be a better way of thinking of it) causing an issue as the winch or plate itself could potentially drive themselves right through the plastic.

Isn't it fun to think about? I went through this when building it...Any way you look at it, even if the box gets destroyed for some reason, the winch isn't coming off of the plate easily, so it would still function.

That's all fine, and believe me I'm not trying to be asshat about this bud. Your 4dr curb wt is just shy of 5k without gear, occupants. That there in real world scenarios is a fail. This is your decisions, and I respect them. But as a experienced off-road enthusiast, this is not ideal.

Curb wt and the resistance that a vehicle creates when unable to move on its own will burn that thing up. This is just me, but before you get out and use this, I would return it and anything that goes with it. Then take that money and use it toward a 9k winch (minimum) and a well built hitch cradle since you are not keen on hard mounting a winch. This way you are not going to be out the money you invested on this setup after its burned up or fails, and you will be still stuck.

I'm just trying to give good advice here. A 4k winch is only good for a ATV, not a 5k full-size vehicle. Not to mention the rope strength is rated at 4k also. Someone can get seriously hurt with this set-up.

I fully understand the limitations of this - As I mentioned, it's totally a portable "better than nothing" solution that wasn't all that expensive. I'm not, in any way, comparing it to a "real" winch setup. If I slide off of a snowy trail, it will probably get me back on it, that's all. It might do more, especially with an RRP, or it might not. I get it...

(side note it's 5500 lbs., not 4k)

Then there is this…….
https://www.bronco6g.com/forum/thre...t-drop-on-two-bolt-weekend-winch-mount.43782/