My version of the RC Hidden Winch install - 2.3MT Badlands Mod Bumper

[Arcnsparks]

Curious about one aspect - the extended handle you have for the clutch release. I had an idea of how I wanted to do this, but when I looked at it I realized that the centerline of the existing handle is under that crossmember, and so I would need some kind of "offset" solution for it. How did you overcome that?

I thought it actually worked out well that it was directly in line. That way I was able to drill through it and made a 3d printed "bushing" to act as a lower support and guide for the rod. The bushing plate then also had a hole for the clip that's on the wiring harness that runs along the top of the crossmember to re-secure as well. I didn't have the bushing installed in this picture, you can just see that it goes through a 1" hole in the crossmember:

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[mds5917]

I thought it actually worked out well that it was directly in line. That way I was able to drill through it and made a 3d printed "bushing" to act as a lower support and guide for the rod. The bushing plate then also had a hole for the clip that's on the wiring harness that runs along the top of the crossmember to re-secure as well. I didn't have the bushing installed in this picture, you can just see that it goes through a 1" hole in the crossmember:

Oh - I didn’t realize you went through the crossmember! 1” is a big hole - you’ve got a lot more guts than me, but I guess you get a bit of wiggle room like that too for alignment. I’ll have to revisit mine. I have my Baja Designs lighting harness and my winch ground line running across the brace tied to that factory harness running as well.

 

[JMB]

Good job.

 

[pfbz]

Great design and fab work!

 

[Jdyount]

Great job! Looks really good. I may try something similar with the 2.7 if I can figure out how to relocate the heat exchanger. Need a warm weekend to do the initial wrenching and measuring

 

[Polish ghost]

Originally posted a few pictures of my install in the "What did you do to your Bronco today" thread and had quite a few questions so thought I'd post more in a thread of its own.

So I went in a slightly different direction than what I've seen others go with my Rough Country Hidden Winch install. Mainly, how I modified the clutch release lever to make it easily accessible. As for the modifications made to work with my Mod Bumper, I morphed the RC skid plate into the BL skid and everything bolted right back up with a small spacer on the front two skid plate bolts. Went with the 12K lb. Badland APEX winch and thought I might have to remote mount the control box but everything fit nicely. So far have been pretty happy with how it all turned out.

For the clutch lever I was able to cut the handle in half and drilled and tapped the now separate top and bottom halves for a 5/16" aluminum rod and a jam nut. I actually tapped it M8 for some flanged nuts I already had. The lever actually lined up perfectly with the radiator cross brace so I drilled a hole through and passed the rod through it I then made a stabilization bracket for the top. There was an existing hole in the top of the fan shroud that lined up nicely and I drilled another for an additional mount point and used plastic push retainers for an OEM look.

There was also a perfect spot for the winch main power disconnect. A quick aluminum bracket and an M8 bolt secured it to an existing brake line distribution block bracket.

Lastly are some pictures of the modifications I made to the RC skid plate. I cut off the portion that had the "RC" cut into it and then flattened the different angles to make things more streamlined. I then show where I mocked everything up to get the front hawse fairlead at an angle I liked.

Little bit of grinding, primer, Rust-oleum Wrinkle Finish and a satin black top coat and it matched the factory finish almost exactly. I called it complete!

Did you lose any ground clearance putting all that on in the front

 

[srotier]

Great work! I wish I had those skills the do the same. I was ready to hit purchase on the RC hidden winch plate and at the last minute realized it wouldn’t fit the mod bumper. Awesome job! When you’re ready to fab version 2 let me know.

 

[BingoBangoBronco]

Originally posted a few pictures of my install in the "What did you do to your Bronco today" thread and had quite a few questions so thought I'd post more in a thread of its own.

So I went in a slightly different direction than what I've seen others go with my Rough Country Hidden Winch install. Mainly, how I modified the clutch release lever to make it easily accessible. As for the modifications made to work with my Mod Bumper, I morphed the RC skid plate into the BL skid and everything bolted right back up with a small spacer on the front two skid plate bolts. Went with the 12K lb. Badland APEX winch and thought I might have to remote mount the control box but everything fit nicely. So far have been pretty happy with how it all turned out.

For the clutch lever I was able to cut the handle in half and drilled and tapped the now separate top and bottom halves for a 5/16" aluminum rod and a jam nut. I actually tapped it M8 for some flanged nuts I already had. The lever actually lined up perfectly with the radiator cross brace so I drilled a hole through and passed the rod through it I then made a stabilization bracket for the top. There was an existing hole in the top of the fan shroud that lined up nicely and I drilled another for an additional mount point and used plastic push retainers for an OEM look.

There was also a perfect spot for the winch main power disconnect. A quick aluminum bracket and an M8 bolt secured it to an existing brake line distribution block bracket.

Lastly are some pictures of the modifications I made to the RC skid plate. I cut off the portion that had the "RC" cut into it and then flattened the different angles to make things more streamlined. I then show where I mocked everything up to get the front hawse fairlead at an angle I liked.

Little bit of grinding, primer, Rust-oleum Wrinkle Finish and a satin black top coat and it matched the factory finish almost exactly. I called it complete!

Was definitely planning to do the same with an ADD bumper!

 

[TripleB]

Nicely done.

 

[The_Axeman]

Great work! Wish I had the capabilities to do this. I don’t suppose you could propose your design to RC so that they’d maybe offer this as an option?
Also, would one be able to use Aux switch #1 instead of installing that main shutoff?

 

[BROCK-O]

Posted similar project a while back. I dig the clutch release lever you've done here. Here's the link if anyone is on the fence.
https://www.bronco6g.com/forum/threads/rough-country-hidden-winch-install-2-3-badlands.32997/

 

[NaturalFlorida]

Well executed installation

IMHO, for my intended use getting through deep Florida rutted mud holes hunting and Arizona Spring, Colorado / Utah Summer trips "On the Rocks" this set up is less than desirable.

I need my winch up out of the water and mud as much as possible.

I need my winch to maximize my approach angle and not reduce the functionality of my skid plate with additional snags .

My use of that setup would destroy the line hook and fairlead in short order.

Just my 2 cents...

 

[USAGUY]

. Wow!

 

[mkennedy009]

OG you have some talent, keep going, I can't wait to see more of your designed.

 

[josedirte]

Originally posted a few pictures of my install in the "What did you do to your Bronco today" thread and had quite a few questions so thought I'd post more in a thread of its own.

So I went in a slightly different direction than what I've seen others go with my Rough Country Hidden Winch install. Mainly, how I modified the clutch release lever to make it easily accessible. As for the modifications made to work with my Mod Bumper, I morphed the RC skid plate into the BL skid and everything bolted right back up with a small spacer on the front two skid plate bolts. Went with the 12K lb. Badland APEX winch and thought I might have to remote mount the control box but everything fit nicely. So far have been pretty happy with how it all turned out.

For the clutch lever I was able to cut the handle in half and drilled and tapped the now separate top and bottom halves for a 5/16" aluminum rod and a jam nut. I actually tapped it M8 for some flanged nuts I already had. The lever actually lined up perfectly with the radiator cross brace so I drilled a hole through and passed the rod through it I then made a stabilization bracket for the top. There was an existing hole in the top of the fan shroud that lined up nicely and I drilled another for an additional mount point and used plastic push retainers for an OEM look.

There was also a perfect spot for the winch main power disconnect. A quick aluminum bracket and an M8 bolt secured it to an existing brake line distribution block bracket.

Lastly are some pictures of the modifications I made to the RC skid plate. I cut off the portion that had the "RC" cut into it and then flattened the different angles to make things more streamlined. I then show where I mocked everything up to get the front hawse fairlead at an angle I liked.

Little bit of grinding, primer, Rust-oleum Wrinkle Finish and a satin black top coat and it matched the factory finish almost exactly. I called it complete!

Very clean

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