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

[GreyZ]

OK. I’m ready to take my beating. Here are photos of my “similar” setup. This will hook (hard attachment) to any of the 4 recovery points on the Bronco.
…or whatever else you might want to use the winch for….

This is nice too. I would probably run a loop instead of the hook on the line end. Soft shackle systems are safer in that respect. This mount plate looks very beefy though.

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[Rick Astley]

You guys in the NW also have something that provides great recovery assistance, that we in the SW don’t often have. TREES to hook to….

Never to late to start planting trees!

 

[n0xlf]

I believe the winch will “stop” or overload way before the line breaks.

I'm going to artificially introduce the failure - A quick release block/latch is probably easiest way but they are expensive. Anyone have one I can borrow for a bit? - I'll pay shipping.

A few thoughts (from an engineer)...

You're also using a synthetic line so there shouldn't be too much stored energy in the pull. Just be double safe and make sure nobody is standing behind the vehicle when winching.

And this is why I suspect the testing will be less than impressive. Some people are suggesting that it's going to break through doubled up 31,000 lb. strap (it would have to, as it's only long enough to go half way up the hood when it's attached), go through my windshield , and enter low earth orbit after taking off my head. The forces involved in this are no doubt to be respected, but they can also be safely controlled/used/tested, even with something like this that looks odd.

M8 (8mm) is basically equivalent to a 5/16 standard bolt. I think you're fine there. My bigger concern would be pulling a bolt head trough the plate. Assuming you drilled appropriate sized holes for the bolts, you will probably be ok. I wouldn't mind seeing a high strength washer just to be safe.

It's as small as I could get it that would allow the bolt to pass through, which is why I didn't add a washer. There's also another steel plate that the winch sits on inside the box, which is the factory mount. As pointed out earlier, that could improve shear strength.

The downside is that its slower, which may be a problem if you only wheel in big groups, but if you wheel by yourself, or with just two then this really makes alot of sense.

I do wheel by myself, which was the inspiration for this and all of the other recovery gear that I acquired (and my pending HF radio installation). I also don't wheel a lot, which is why this made sense for me. I would never use this in a group, as it takes too long to deploy.

OK. I’m ready to take my beating. Here are photos of my “similar” setup.

You didn't learn from me?

 

[MNBronc]

"I would be pretty sure Yankum does not make their own rope, but buys it from a rope manufacturer and then makes the splices. US or China????"
[/QUOTE]


Surprisingly Yankum does make their own ropes. I would have bet the same as you.

 

[RHeinz]

"I would be pretty sure Yankum does not make their own rope, but buys it from a rope manufacturer and then makes the splices. US or China????"

Surprisingly Yankum does make their own ropes. I would have bet the same as you.

[/QUOTE]
Excellent, I stand corrected. Thanks for posting!

 

[TheGriffin1313]

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.

Obviously 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).

The idea is brilliant outstanding…. The hardware execution needs some proofing but if done correctly this is a wonderful solution

 

[Sewie]

Keep in mind that a winch's full pulling power is only on the last layer. The pulling strength for that 5500# winch on the first layer is only ~3500#. HF also doesn't list the breaking strength for that line but most 1/4" lines are around 9000-10000#. So for those saying to snatch block, not only do you only have 50' of line to work with, you'd be effectively at the breaking strength of the line.

 

[RHeinz]

This is nice too. I would probably run a loop instead of the hook on the line end. Soft shackle systems are safer in that respect. This mount plate looks very beefy though.

Yes, that’s a good comment. The winch mount modifications might be slightly more complex to limit the bending angles in the soft shackle. The “pin” mount of the hook was pretty simple and solid.

If I recall correctly, the winch weighs 22 lbs. I also off-road solo and thought about connecting a soft shackle while somehow supporting the 22 pound winch. The steel hoist hook seemed simpler (18,000 lb. working load) since I can hold the winch with two hands and just hook it in on the front shackles or rear loops. I do carry two sets of soft shackles and two snatch blocks along with other rope and straps. I am lacking a spare synthetic 50’ winch line which I plan to purchase in the near future.

 

[GreyZ]

Keep in mind that a winch's full pulling power is only on the last layer. The pulling strength for that 5500# winch on the first layer is only ~3500#. HF also doesn't list the breaking strength for that line but most 1/4" lines are around 9000-10000#. So for those saying to snatch block, not only do you only have 50' of line to work with, you'd be effectively at the breaking strength of the line.

Snatch block does not change the line loading.

 

[RHeinz]

Keep in mind that a winch's full pulling power is only on the last layer. The pulling strength for that 5500# winch on the first layer is only ~3500#. HF also doesn't list the breaking strength for that line but most 1/4" lines are around 9000-10000#. So for those saying to snatch block, not only do you only have 50' of line to work with, you'd be effectively at the breaking strength of the line.

The line load will never exceed the winch capacity no matter how many snatch blocks are in use. However, the “speed” of the winched object is cut in half when a snatch block is added.

Warn indicates a winch should be sized a 1.5 times the vehicle weight. For the Bronco 4D, SAS, 2.7L, this is less than 9,000 lbs. With a snatch block on a 5,500 lb. winch you can pull at a force of 11,000 lbs. at the drum of the winch as you pointed out. I would always try the winch first without the snatch block. How often do you really need a 12,000 lb. winch?

Again, this thread is about we folks who off-road SOLO. As I have said previously, a front mounted winch is great for helping others that are compromised but not very flexible for solo recovery. Again, MY OPINION.

 

[Sewie]

Snatch block does not change the line loading.

The line load will never exceed the winch capacity no matter how many snatch blocks are in use. However, the “speed” of the winched object is cut in half when a snatch block is added.

Correct, my bad. Load doubles on the snatch block and its attachment, not the line itself.

That aside, IMO that winch and line are still undersized for a mid-sized SUV. Pulling a truck up an incline in neutral does not require the same force as pulling one out of mud or off of rocks.

 

[Bruno]

This feels like it was written by a sales bot, but none the less...

Disadvanatges.

• When I'm knee deep in mud instead of pulling a single cable out of my bumper I haul out my 50lb suitcase, spare car battery, and rig up my portable death trap. I pray to my deity the battery doesn't tip over in the mud

When you are knee deep in mud.... simply ask yourself: "Am I having fun? Did I do this on purpose?"

 

[RHeinz]

Pulling a truck up an incline in neutral does not require the same force as pulling one out of mud or off of rocks.

Absolutely!!

However 11,000 lbs of force IS 11,000 lbs of force regardless of where it is coming from or what you may be doing. You can probably generate 11,000 lbs of pulling force with a 1/16 HP motor and a HUGE planetary gear system. It’s just not going to move things very fast and that is what we are compromising with these smaller winches. To me, speed isn’t a factor. If I’m stuck SOLO, time is one thing I will have a lot of.

 

[JBlanco]

All I could think of when reading "winch in a box"

 

[Greasyfingers429]

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.

Obviously 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).

Nice idea with that kit, and well documented . I wanted to do this with my hitch-mounted 12,000lb winch setup, and mount it rigidly to a front receiver when I need it. There are no front receiver kits yet, so this might be the only removable front winch option.

I kinda made one of these little ATV sized winch kits for use around the yard to pull trees, drag things onto my trailer, etc. But to recover my Bronco, I went with the 12,000 lb winch. Something that wasn’t obvious until I read the manual is the winch rating drops for every layer of cable on the drum (simple physics at work). The 5th layer on mine is half the rated capacity!

Have fun, be safe!

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