Bumper integrated winch mount - product dev questions

Couple of design changes we are making to the FJ mount that will be incorporated in the Taco mount.

1. Light tabs. There is a height restriction in that the opening above the mount is only 3" on both models. So really the only light, in our Sirius line, you can mount is the 2" (has a 3" housing). We will base the mount tab on this light but move it from the outside edge a bit in case you find something that is the same height but wider... like a 6" light.

2. We are going to move the winch mounting holes back about 1/2" to better center the winch.

3. Adding two more drain holes under the winch. While I haven't seen any issues with drainage or accumulation of mud this will help to prevent that under heavy usage.

4. Adding slider plates on the mounting ears. I'll have to show pics once they are built. Basically these will reinforce the mounting ears and act like washers over the elongated mounting holes. Again, never any issues but just a good idea I think.

Other than that it's all about the facia/valance and how it meets the bumper cover. We will curve it under a bit further than the FJ and have integrated mounting ears pointing rearward to act as torque arms....again, pics will tell the tale.

Some more pics are over on our G+ if you care to see.

We will hit it again tomorrow.

 

Most definitely. While I'm dying to get this 05+ ready I'll have to admit that I'm pretty intrigued about the 12+ as I think it lends itself to a pretty cool solution. We shall see.

 

Sweet, this seems like its gonna be a well thought out product

 

I am very interested. Enjoying the progress and look forward to the finished prototype!

 

Well... this has been a tad more difficult than anticipated but I think we have solutions.

TIME FOR SOME INPUT

Keep in mind that we do this old school... measure, cut, fit and repeat. Just good ol fashioned "hmmmm. that looks like crap" "that doesn't fit" and so on.

1. We built a wider fascia basically like the FJ design... but wider just to get a visual start. Two issues. Too much protrusion below and front and the lines just don't look right (ignore the vertical fit left and right)



You can see what happens when you see the side view:


Obviously that's not going to fly. But there is another issue, the factory recover point/hoop that is welded on to the subframe. You can see it at the far end:


You can see how we are addressing the torque 'straps' by tying in to the subframe with the fascia/bash plate:


2 thinks have to happen.
1. The front needs to go back about 1/2" which means the winch tub has to shink. That's ok there is room to spare, we just need to move the winch mounting holes back 1/2"
2. The angle of the bash plate needs to be closer to 30 deg instead of 45, pretty much along the line of the top of the metal bar from the bend at the winch tub to where the bash plate meets the subframe which you can see in previous pics.


The problem is that the oem recovery point is in the way so we are forced to cut a relief hole OR the customer would need to remove the recovery point by torch or cutoff wheel as it's welded on. You won't really need access to it as our mount will have shackle mounts.

Obviously fascia will be boxed in on the sides and gusseted appropriately.

Continued below.

 

hmm, sounds like something that would do well as an option, letting the end user pick whether to cut off the loop or have a hole cut in the mount

 

Something like this:




Now, we may find that cutting a large hole...say 4 or 5" square would give you access to the recovery point... but for what reason? If you have shackles.

Really to do this right the recovery point needs to come off... at least part of it... but not everyone has a 4" cut off disc or torch sitting around.

I kind of like the 'bulldog' look of the fascia above but it takes up some approach angle and initial clearance below.

 

progress looks good so far...............

i have to agree it could be left up to the buyer to decide to have the re leaf hole cut or not..

for me i would just cut off the factory hook since as u stated your bumper has shackle mounts.

just my 2 cents..

and it looks good so far.

 

Me.. I'd cut the puppy off... it's useless at this point and in the way but here's the kicker. making two different versions and stocking them is a no go if you want to keep pricing down.

That's the kicker. One must apply the KISS principle, a simplified design to permit efficient production in order to keep pricing down.

 

just another option i was thinking about after seeing your winch tray design.. couldn't u just offer the winch tray for sale by itself so the end user could mount it up behind the stock bumper and have the winch come out thru it..

this was the design i was trying to come up with but just gave up as i have too many other things going on right now..

i like the hidden hitch design but did not want the winch lead coming out where my tag was supposed to be
i wanted it to be below the tag.. actually right where yours comes out...

just a thought for ya.........

 

Too bad, I was hoping this system would allow the use of the factory or similar skids. Call me silly but I like the way they look.

 

Many (most) plate bumpers also require the removal of the stock tow mount.

You can also move the whole winch plate up an inch or two if that would make it easier.

 

cut the dam thing off then.. LOL.............

 

If you're in no danger of smashing the factory skids, it's likely you'll never be in a position to need a winch

 

The intent is to build a mount that offers bash plate protection up front, otherwise you could just go with what is on the market and cut a hole in your bumper cover.

We aren't pulling any skids, all of the factory stuff is still on there... at least what is on this truck.

If you are talking about this plate then no, it would have to go:


See the big ol holes below? They are to reach the factory recovery points (go look under yours to see what I'm talking about). I'm trying to stay away from that.

 

Looking good man! Excited to see the end result!

 

Don't want to move it up or you will start losing vertical space for integrated solenoids and reaching the winch clutch lever/control. We have it on the right vertical plane I think.

 

This is what you need to do. I love my hidden winch, but the factory fascia has taken a beating in the rocks. Having some bash protection would be ideal for this.

 

I can't wait to see what you come up with for the '13. I don't need hi-clearance and like how the truck looks stock. I'm hoping you come up with my answer.

Besides, it gives me the opportunity to buy from the home state.

 

the only behind the bumper mount i see on the market is the hidden mount and it puts it in the open area, where the black plastic grill this is.. i cannot have it there as i need to run a front tag..

i would much prefer it to come out in the bottom plastic part right where your winch mount would be..

but i do understand about having protection up front..