Custom Portable Winch Build

[4runr30]

Portable Winch Build
I've wanted a portable winch for several years now and finally got around to doing it. For those who will ask- YES I did look into bumpers from shrockworks,ARB,and many others but opted for a portable setup so I can winch from either the front or the back and I can take if off when not needed. Another plus was I wasn't required to upgrade my suspension. I wanted a custom winch mount since most on the market offer very little protection for the winch itself. So here we go...

First I started with cold-rolled steel:
44" of 3/8X7" and 6" of 3/8X3"
24" of 1/4"thick 2" square tubing
Smittybilt XRC8 Winch
Battery disconnect switch
Disconnect switch mount

Metal was then cut into 2 plates of 7" wide X 22 long" used for a base and front plate.
Then I cut 2 peices of 3" wide X 7" long for the sides.
I used 1/4" thick 2" square tubing to connect with the Curt front receiver (part# 31367)

Holes where then drilled and angles where cut using a drill press and a cutting wheel.

I then found a buddy who welds and fed him beer!

After all the welding I still had to use a flap wheel to clean it up for paint.
I used 3 coats of rust proof primer followed by 4 coats of semi gloss black rust proof paint. I thought about going the powdercoat route but opted for the rattle can for ease in touch up later on.

Thinking I was nearing the finish line I still had to modify the Curt front receiver (part #31367). This receiver is designed to work with 06-09 4runners and mounts to 4 bolts that hold the front bumper horns and utilizes the front tow hooks. The problem I ran into was the 06-09 tow hooks are slanted at a 45 degree angle and the 03-05 hooks are at 90 degrees. To solve this problem I searched the forum and followed their example by cutting the bottom mounts off of the receiver and had them rewelded at 90 degrees.

After all this was done it was time to run the wiring.
Smittybilt provides wiring so I bought 2 sets of Bulldog winch connectors off Amazon. The connectors retail for around $50 including shipping.They come with nice rubber covers that I've yet to install.

I didn't want the winch to be "Hot" when not in use so I used a battery disconnect.

As for the ground I just bolted it to an existing stud used for the push bar.

After all this I was finally ready to bolt everything together for the almost finished product!

Today I ventured up a local fire road to test the winch on a fairly steep grade.

Results

The winch boggs down when under a heavy work load but still gets the job done. If I had a rock crawler or was doing competition I would def opt for a faster line speed, ut for what I do it will work fine.

Still to Come

I still need to wire an outlet to the rear receiver and cut off the long bolts on the mount holding the battery disconnect. I am not happy with how low the mount sits so I am placing order for the new CBI behind the bumper mount!!!! See link http://www.toyota-4runner.org/4th-gen-t4rs/85730-new-hidden-front-receiver-hitch.html Hopefully I can send CBI payment and have their set up within the next few weeks. I also need to replace the fairlead bolts with SS bolts since I was inpatient and originally bolted it up with grade 5 zinc coated bolts. Other than that its done. Even at the low height it is at now I only had trouble with the approach angle twice while offroad today. Hopefully this project won't have to be used too often but Ill atleast have it if I need it. Let me know what you think...:cheers:

 

[blcktpgsr]

Not bad at all. Yeah I'd be more confident hittin' up the trails alone knowing I have a back up recovery system on board.

 

[topdown4runner]

Looks good.
I did the same thing for my '87. I wanted one winch for all applications on all my trucks.
Still need to do the quick connects, wire it up for the rear.
Also need to add a receiver on the front of my T100, wire up both front and back of the T100, etc.... damn, I'm slow...

 

[fatkins]

Nice writeup..Thinking about the CBI mount as well and would be interest to hear your experince after trying it out.
I run similar connectors on the front, as well built a set of cables for the rear. I haven't finalized a permanently install of the rear cable as yet.
I have a dual battery setup using painless isolator with winch connected to primary battery as recommended. Running fridge and GPS off secondary battery.

 

[4runr30]

Looks good.
I did the same thing for my '87. I wanted one winch for all applications on all my trucks.
Still need to do the quick connects, wire it up for the rear.
Also need to add a receiver on the front of my T100, wire up both front and back of the T100, etc.... damn, I'm slow...

Good lookin 87! Haha as for bein slow this project took alot more time than expected...

Nice writeup..Thinking about the CBI mount as well and would be interest to hear your experince after trying it out.
I run similar connectors on the front, as well built a set of cables for the rear. I haven't finalized a permanently install of the rear cable as yet.
I have a dual battery setup using painless isolator with winch connected to primary battery as recommended. Running fridge and GPS off secondary battery.

Im excited about it. Just wish Id found it before buying the Curt. Ill let you know how it works out. Supposed to ship out tomorrow!

Not bad at all. Yeah I'd be more confident hittin' up the trails alone knowing I have a back up recovery system on board.

Agreed. Hopefully Iwont have to use it though.

 

[runn4hunt]

Smittybilt XRC8 Winch

Nice joob. How I see you are welder. I have a 2005 4runner you think does it fit in my car? By

 

[4runr30]

Nice joob. How I see you are welder. I have a 2005 4runner you think does it fit in my car? By

Im certainly not a welder. Had a buddy do the work. If your asking will it pull your t4r then yes. It will fit on the vehicle with the right front receiver and winch mount.

 

[4runr30]

CBI receiver installed

First off thanks to Nathan and his crew at CBI Offroad for such a great product! When I had questions I always received a reply within a timely manner. As for install all you need is a phillips head screwdriver and a deepwell socket wrench.
Here are some before/after pics.

Before with the Curt receiver and low ground clearance

After with the CBI receiver

 

[gm350reratliff]

Very nice! Have you pulled the 4runner with the CBI front receiver yet? Curious as to how strong it is. I'm thinking of ordering a CBI front receiver as well.

 

[4runr30]

Very nice! Have you pulled the 4runner with the CBI front receiver yet? Curious as to how strong it is. I'm thinking of ordering a CBI front receiver as well.

I havent used the winch since installing the CBI receiver. I dont anticipate any problems though. It is literally the front frame with 8 attachment points, VERY STRONG. Ill let you know how it goes when I do need to do some winching.

Side note: Curt front receiver for sale. Moded to fit 03-05 tow hooks. $100 plus shipping. Willing to negotiate price depending on shipping cost. I have $150 in it.

 

[CAN-03runner]

Have you had a chance to go test winching with this mount?

From what I can see and understand it mounts like their winch bumper would mount. And It does include a side brace bolted into that side hole right next to the factory tow rings. Am I understanding this correct?

 

[4runr30]

Have you had a chance to go test winching with this mount?

From what I can see and understand it mounts like their winch bumper would mount. And It does include a side brace bolted into that side hole right next to the factory tow rings. Am I understanding this correct?

You understanding of the mounting is correct. The tow hooks are un-used with the CBI system. The winch works great. Ive yet to use it for its intended purpose but it was wicked at pulling trees out of the ground last wkend.