Terrano Winch Bar Build (Kiwipetes)

[Drurban]

It is starting to take shape now and looking good, and you have covered all load stresses that will be applied to the bar.

Great work keep it up.

[kiwipete]

It is starting to take shape now and looking good, and you have covered all load stresses that will be applied to the bar.

Great work keep it up.

Thanks for the support. It has been a long hard slog, and back braking too I might add. Thank god for carpet on the concrete floor. Bloody hard kneeling on the cobbles outside though.

Winch will need to be striped down before I rewire it too. I have to rotate the position of the clutch release lever so it sits vertical and put some fresh grease in it as it is as stiff as a stiff thing on national stiff day when free spooling.

[kiwipete]

Not too much to report today.
I managed to get the bars shortened up on both sides, welded, ground and sanded. No tabs on yet for indicators nor have I bothered with the diagonal brace; unsure if I will now as I would have to cut some trim away for clearance.
All up there are 18 bolts holding the whole structure in place, is this enough?

I wonder if I should get the bars powder coated, or just sand them back and paint? The etch primer I put on them seems to react with whatever they have been painted with, so one way or another they have to be stripped bare.

Does anyone know what powder coaters there are here in Chch and roughly what they would charge to do these bars? I know they need to look at them for a quote, just wondering if anyone has had something similar done.

[KIWI_TERRANO]

Not too much to report today.
I managed to get the bars shortened up on both sides, welded, ground and sanded. No tabs on yet for indicators nor have I bothered with the diagonal brace; unsure if I will now as I would have to cut some trim away for clearance.
All up there are 18 bolts holding the whole structure in place, is this enough?

I wonder if I should get the bars powder coated, or just sand them back and paint? The etch primer I put on them seems to react with whatever they have been painted with, so one way or another they have to be stripped bare.

Does anyone know what powder coaters there are here in Chch and roughly what they would charge to do these bars? I know they need to look at them for a quote, just wondering if anyone has had something similar done.

Try euroblast in hornby , hes pretty good with prices

[aroma]

trotters, maces rd end of wickham st
why don't you just leave just painted till you used them and happy with how it all works

[kiwipete]

trotters, maces rd end of wickham st
why don't you just leave just painted till you used them and happy with how it all works

Thanks, I don't plan on getting it done this month, will undercoat the bars until as you say, I am happy with them. I am sure there will be a tweak here and there yet.

[kiwipete]

More "Bling" arrived today.



These lights have an orange lamp in them that I will replace with a clear LED lamp to use them as "day time" lights as the cheap (replaced once already) LED ones I have crapped out; again!

Now I can finish the tabs for the front lights & indicators.
I got a "cash" quote today of $100.00 to Zinc and powder coat the bars. I think this is a good deal, also heard of a guy close to the powder coater who might sandblast them for $60.00. Need to go and pay him a visit tomorrow.

[KIWI_TERRANO]

Have you tried euro blast?

They do sandblasting painting powdercoating and other little magic things

[kiwipete]

Have you tried euro blast?

They do sandblasting painting powdercoating and other little magic things

No I haven't unfortunately sorry, wrong side of town for me.
The one I went to is just around the road from work and the sandblaster is behind him too. Going to see the sand blaster tomorrow. I thought his price was good enough for me so I will leave it at that thanks.

[u13turbo]

Looking bloody good Pete, looks like your a good fabricator aswel.

[kiwipete]

Looking bloody good Pete, looks like your a good fabricator aswel.

Cheers, don't know if I would go that far.

[chrome]

did you find any caps for your tubes, steel and tube have weld on caps in all the line pipe and nominal bore tube sizes

[kiwipete]

did you find any caps for your tubes, steel and tube have weld on caps in all the line pipe and nominal bore tube sizes

No, I have not bothered to look any further yet but thanks for the hint.
I am getting ready for my mid year holiday so will look into it all when I'm back.

[chrome]

bout 7 bucks each mate. you can get knock ons as well but we know u can weld

[coxsy]

I used knock on ones with three tacks to hold them more rounded edges

[sibainmud]

Looking real good Pete,
Wish I had those toys to play with too.
Sorry couldn't get these up sooner.
Left camera in truck on the side that floods
A week in warm dry place and it's good as gold
These pics show the top mounts. You may have to grind a bit out of hole under the front guard to accommodate the body lift in order to get straight at these two bolts.





Off to wash it now
Cheers,

[kiwipete]

Thanks Simon, in one of the pics above you will see how I made a brace out of the original bumper mounts, using the two stock bolts.

I will have to test it out in anger later in July when I get back from my holidays and have it all finished.
It's just a matter of finding someone who makes the Hi-Lift jack T slotted plates and making the top chequer plate mounting tabs and two aerial mounts so I can get it all powder coated.

[kiwipete]

Just an updated picture of where I have got to with the winch bar.
I have put it on hold until mid July now as I will be away for a while.



Still on the lookout for the plates for a Hi lift jack that have the T cut into them; does anyone knows where I can get them?

[chrome]

cad drawn and plasma cut would be easy, must be someone in chch that can sort it

[kiwipete]

cad drawn and plasma cut would be easy, must be someone in chch that can sort it

You are probably right there thanks, I will do some serious searching when I'm back; just thought I'd put some feelers out there.

[kiwipete]

I used knock on ones with three tacks to hold them more rounded edges

Cheers coxsy, that looks like a plan indeed.

[chrome]

if you can sketch it and send it to me i will draw it up. I know a guy in chch that has access to plasma, he is on here too

[kiwipete]

if you can sketch it and send it to me i will draw it up. I know a guy in chch that has access to plasma, he is on here too

Will do in July thanks.

[kiwipete]

While I am waiting for prices for the replacement parts to my Runva winch I have done some more alterations to the winch bars................. It seems that the GEW10000 model is not made any more.


I picked a bloody cold day today to do cutting, grinding, welding and painting, thank god for a good fire in the workshop!

Chequer plate tabs welded in place.


Trial fit of chequer plate.


Box section tack welded in place for the fairlead roller, the roller is just sitting in there to show clearances.


Painted her up to stop rusting as it will be another week before I get back to it. I left the Co2 bottle turned on when having a break and the last 1/4 of the bottle escaped out the door! Seems I have more than a small leak in the gauge/tap section?
The rest of the welding will have to wait till I get the bottle filled again.


I have also decided to just spray paint the bars now instead of getting it all powder coated. 1, cost and 2, easy to quickly respray when it gets scratched.
There is just a small amount of sanding to do to do the final top coats of spray paint.

What you do not see in the pictures is the two aerial mounts. I removed the Z brackets from the guard/bonnet areas and cut the mounts off them and welded to the top most section of the bars where they go over the headlights.
I had to do this because I cannot see the bars over the bonnet from the drivers seat and needed a marker of some sort. Parking behind another car is a little worrying.

[kiwipete]

Not much to report, alas this part of the build has come to an end.

Here are some poser shots for all you picture junkies. Only thing missing is the spotlights, the paint is still a tad tacky to put them on today.









I see looking under there that a couple of bits n bobs could do with a fresh coat of paint...........

Action shots to come just as soon as it gets a little warmer.

[Drurban]

Looking good there Pete even with that paint job looks bloody mint good work.

Also it is good that you mentioned that they are not making the 10,000Lbs winch, it will give me an Idea of which one to get for my next one.

Cheers

[Sketchy_Racer]

Looks great Pete, your pictures and discussions on here were very helpful for me as I built mine. Unfortunately I don't have a camera so didn't get any pictures of the build but I will try get some of the completed bar.

Tested out my winch today after getting the second battery in and wired in, chucked it on the fence post and went to pull the truck up the drive, turns out the truck is heavier than I though and ripped the fence post out...

With the bar and winch fitted I dropped about 50mm in the front so glad I have torsion bars and can wind them back up. The extra weight is really good as I have Calmini heavy duty torsion bars and without the extra weight the spring rate was wrong and was far to firm but now is good.

Cheers,

Sketchy

[kiwipete]

Ok, the final bit of "Bling" was added to the truck today.
I wanted to use the new Hawse fairlead that came with the winch, but it was going to be too much of a mission to install it in my setup. I decided to keep the original roller fairlead but the rollers were damaged by the steel wire rope and I did not want to use them with the new synthetic rope.
I tried a swap with someone, but the new rollers are a different size from mine.
A good mate made me some nice new stainless rollers. These buggers will not rust

Old rollers


New rollers


Mounted


Spose I should get out there and test it now.

[SMOKEY]

Well done Pete, for an old Liney with home handyman talent and tools you have made a very profesional job. This goes to prove that you,

CAN TURN SHIT INTO HONEY,

FITZY.

[kiwipete]

Well done Pete, for an old Liney with home handyman talent and tools you have made a very profesional job. This goes to prove that you,

CAN TURN SHIT INTO HONEY,

FITZY.

Cheers Fitzy.
I could not have done it without a whole lot of help and assistance from a huge bunch of good bastards.

What to do with the license plate, it will not last two minutes there off road. Maybe I will mount it on a hinge?